Page 2: Safety Notice
ESSENTIAL NOTES BEFORE PROCEEDING Safety Notice Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles, as well as the personal safety of those performing repairs. This information outlines procedures for servicing and repairing vehicles using, safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures, to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.
Page 3 PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant.
Page 4 Servicing Your Vehicle Safely It is virtually impossible to anticipate all of the hazards involved with automotive maintenance and service, but care and common sense will prevent most accidents. The rules of safety for mechanics range from "don't smoke around gasoline," to "use the proper tool for the job."...
Page 5 DON'TS Don't run the engine in a garage or anywhere else without proper ventilation--EVER! Carbon monoxide is poisonous; it takes a long time to leave the human body and you can build up a deadly supply of it in your system by simply breathing in a little every day. You may not realize you are slowly poisoning yourself.
Page 6 Fig. 1: Always support your vehicle on jackstand while working underneath Fig. 2: If you're using portable electric tools, make sure they're grounded, preferably at the plug by a three wire connector...
Page 7 ENGINE ELECTRICAL Service Precautions Before servicing any vehicle read all of the following precautions that deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: If the battery is removed for any reason, ensure that it is reconnected with the correct polarity.
Page 8 Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons causing potentially serious (also time- consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection.
Page 9 Ignition System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information NOTE: For information on understanding electricity and troubleshooting electrical circuits, please refer to chassis electrical. Coil on Plug (COP) System The coil over plug system was developed so that spark and spark timing could be better controlled on an individual cylinder basis.
Page 10 on the application, these slots are spaced around the ring in a specific configuration. As the ring rotates, the slots pass between the hall-effect switch, and alternately turns the voltage off and on. When a slot aligns with the hall-effect switch, the controller sees voltage on the signal line.
Page 11 Secondary Spark Test This spark tester looks just like a spark plug. Attach the clip to ground and crank the engine to check for spark. This spark tester has an adjustable air-gap for measuring spark strength and testing different voltage ignition systems.
Page 12 Attach the clip to ground then crank the engine to check for spark. This spark tester is the easiest to use. Just place it on a plug wire and the spark voltage is detected; the bulb on the top will flash with each pulse. NOTE: The best way to perform this procedure is to use a spark tester (available at most automotive parts stores).
Page 13 The Air Gap type must be adjusted to the individual spark plug gap specified for the engine. The last type of spark plug tester looks like a spark plug with a grounding clip on the side, but there is no side electrode for the spark to jump. NOTE: The last two types of testers allow the user to not only detect the presence of spark, but also the intensity of the spark.
Page 14 Firing Orders 4.2L Engine 1-5-3-6-2-4 5.3L & 6.0L Engines 1-8-7-2-6-5-4-3 Ignition Coil-On-Plug Removal & Installation 4.2L Engine To Remove: 1. Remove the air cleaner outlet resonator from the engine. Ignition coils...
Page 15 2. Disconnect the ignition coil connectors. 3. Detach the ignition coils from the engine. To Install: 1. Attach the ignition coils to the engine. Torque the retaining bolts to 89 in-lb (10 Nm). 2. Connect the ignition coil connectors. 3. Install the air cleaner outlet resonator to the engine. 5.3L &...
Page 16 2. Disconnect the spark plug wires from the ignition coils. 3. Disconnect the ignition coil connectors. 4. Detach the ignition coils from the engine. To Install: 1. Attach the ignition coils to the engine. Torque the bolts to 71 in-lb (8 Nm). 2.
Page 17: Charging System
Charging System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information An automobile’s charging system provides electrical power for the operation of the ignition, starting system, and all electrical accessories. The battery serves as a storage device holding a supply of electricity and is regenerated by the generator when the engine is running.
Page 18 Generator Voltage Test 1. Make sure the engine is OFF, and turn the headlights on for 15-20 seconds to remove any surface charge from the battery. 2. Using a DVOM set to volts DC, probe across the battery terminals. 3. Measure the battery voltage. 4.
Page 19 under and overcharging is caused by a defective generator or internal regulator. Replacement of these components will then repair the condition. Removal & Installation 4.2L Engine To Remove: 1. Disconnect the negative battery cable from the battery. 2. Remove drive belt from the pulleys. 3.
Page 20 5. Detach the generator from the engine. 6. Detach the battery positive cable from the generator. To Install: 1. Attach the battery positive cable to the generator. Torque the nut to 80 in-lb (9 Nm). 2. Attach the generator to the engine. Torque the bolts to 37 ft-lb (50 Nm). 3.
Page 21 5. Detach the generator from the engine. To Install: 1. Attach the generator to the engine. Torque the bolts to 37 ft-lb (50 Nm). 2. Attach the generator cable to the generator. Torque the nut to 80 in-lb (9 Nm). 3.
Page 22 Generator Battery Control Module Removal & Installation 2007 To Remove: 1. Disconnect the negative battery cable from the battery. 2. Disconnect the generator battery control module connector. 3. Remove the negative battery harness from the engine compartment. 4. Mark the position of the clips on the negative battery harness. 5.
Page 23 2. Install the new generator battery control module by sliding it onto the negative battery harness and inserting the tab under the negative battery cable terminal cover. 3. Secure the generator battery control module to the negative battery cable by wrapping electrical tape around the module leg.
Page 24 atmosphere. Over time moisture in the brake system will lead to corrosion and damage to internal parts. Also, a sufficient level of moisture in the fluid can dramatically lower its boiling point. Should temperatures during hard braking (mountain driving, trailer towing, racing, etc) allow the brake fluid to boil, you could experience and sudden and complete loss of braking ability.
Page 25 recommendations with your manufacturer, you will probably find that they have listed those intervals for "SEVERE" usage and not "NORMAL." Maybe it is just a play on words. Just remember that it is your money (that you are driving around every day) and possibly even your life (kept safe by tires and brakes .
Page 26 Fig. 3: Typical body and undervehicle maintenance locations (Refer to chart for descriptions)
Page 27 Fig. 4: Typical lubricants, from left to right: Engine Oil; Gear Oil; ATF; Wheel Bearing Grease; Brake Fluid; Chassis Grease; White Grease; and Silicone Spray...
Page 28 Fig. 5: Special tools make lubrication easier, from left to right: Oil Suction Gun; Oil Can; Funnel; Grease Gun; and Wheel Bearing Packers...
Page 32 ENGINE ELECTRICAL Service Precautions Before servicing any vehicle read all of the following precautions that deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: If the battery is removed for any reason, ensure that it is reconnected with the correct polarity.
Page 33 Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons causing potentially serious (also time- consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection.
Page 34 Ignition System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information NOTE: For information on understanding electricity and troubleshooting electrical circuits, please refer to chassis electrical. Coil on Plug (COP) System The coil over plug system was developed so that spark and spark timing could be better controlled on an individual cylinder basis.
Page 35 Hall-Effect Device Another device that can be used to create a triggering signal is a hall-effect device. A hall- effect device can be thought of as a solid-state On/Off switch. The hall-effect switch is a three-wire device that must receive a power and ground. The hall-effect switch is used in conjunction with an interrupter ring with a series of slots or openings cut into it.
Page 36: Starting System
Starting System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information The starting system includes the battery, starter motor and solenoid, ignition switch, circuit protection and wiring connecting all of the components. An inhibitor switch located in the Transmission Range (TR) sensor is included in the starting system to prevent the vehicle from being started unless the transmission is in PARK.
Page 37 Starter Testing Starting System Voltage Drop Tests NOTE: The battery must be in good condition and fully charged prior to performing this test. There are three area of the starter motor circuits that voltage drop test can be performed on. These include: The starter feed circuit The starter ground circuit The starter solenoid.
Page 38 Starter Solenoid 1. Disable the fuel system by removing the fuel pump fuse or the fuel pump relay. 2. Verify that the vehicle will not start. 3. Connect the positive lead of the voltmeter to the case starter B+ terminal. 4.
Page 39 Removal & Installation 4.2L Engine To Remove: 1. Disconnect the negative battery cable from the battery. 2. Disconnect the brake booster hoses from the engine. Starter 3. Remove the positive battery cable and s-terminal lead from the starter. 4. Remove the starter from the engine.
Page 40 To Install: 1. Install the starter to the engine. Tighten the nut and bolt to 37 ft-lb (50 Nm). 2. Install the positive battery cable and s-terminal to the starter. Tighten the battery cable nut to 80 in-lb (9 Nm). Tighten the s-terminal nut to 20 in-lb (2.3 Nm). 3.
Page 41 4. Detach the wire harness from the transmission oil cooler line bracket. 5. Detach the transmission oil cooler line bracket from the engine. 6. Remove the right transmission cover bolt from the transmission cover. 7. Detach the starter from the engine. 8.
Page 42 Starter Relay Removal & Installation To Remove: 1. Remove the underhood fuse block cover. 2. Find the starter the relay. 3. Use the J 43244 relay puller pliers to remove the relay. To Install: 1. Place the relay in the same orientation as before it was removed. 2.
Page 43 ENGINE REPAIR Precautions Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: Always wear safety goggles or some type of eye/face protection when working with, around or under a vehicle.
Page 44 Cleanliness and Care, Shop Practice It should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. When any internal engine parts are serviced, care and cleanliness is important. When components are removed for service, they should be marked, organized or retained in a specific order for reassembly.
Page 45: Engine Mechanical
Engine Mechanical WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section.
Page 46 Camshaft Removal & Installation 4.2L Engine To Remove: 1. Remove the camshaft cover from the cylinder head. 2. Remove the bolt from the intake camshaft sprocket. 3. Remove the bolt from the exhaust camshaft actuator. J 44222 Installation 4. Attach a J 44222 camshaft sprocket holding tool to the camshaft sprockets. 5.
Page 47 Camshaft cap removal and installation Detach the camshafts caps from the cylinder head. Make sure to place the caps in a rack to ensure they are installed in the same location they were removed from.
Page 48 Camshaft removal and installation 7. Remove the camshafts from the cylinder head. To Install: 1. Use clean engine oil to coat the camshafts. 2. Install the camshafts into the cylinder head. 3. Attach a J 44221 camshaft holding tool to the camshafts. Make sure cylinder 1 is at top dead center and the camshaft flats are facing up.
Page 49 10. Install the bolt and washer into the exhaust camshaft actuator. Torque the bolt to 18 lb-ft (25 Nm). 11. Use a J 36660-A torque/angle meter to turn the exhaust camshaft actuator bolt an additional135 degrees. 12. Install the camshaft cover onto the cylinder head. 5.3L &...
Page 50 Camshaft sprocket removal and installation 6. Detach the camshaft sprocket with the timing chain from the camshaft. CAUTION In order to prevent damage to the piston assemblies or valves, do not turn the crankshaft assembly after the camshaft sprocket has been removed. Camshaft retainer removal and installation 7.
Page 51 Camshaft removal and installation 8. Install a M8-1.25 x 4.0 in (M8-1.25 x 100 mm) bolt into each of the bolt holes in the front of the camshaft. 9. Rotate and pull the camshaft out of the engine block using the bolts as a handle. 10.
Page 52 4. Attach the camshaft retainer onto the engine block. Torque the bolts to 18 ft-lb (25 Nm). 5. Attach the camshaft sprocket with the timing chain onto the camshaft. Make sure the timing marks on the camshaft and crankshaft sprockets are lined up. Torque the bolts to 26 ft-lb (35 Nm).
Page 53 Removal & Installation 4.2L Engine To Remove: 1. Remove the cooling fan and drive belt from the engine. 2. Remove the crankshaft balancer bolt from the crankshaft balancer. Crankshaft balancer 3. crankshaft end protector into the end of the crankshaft and use a 3 jaw puller to remove the crankshaft balancer.
Page 54 To Install: 1. Lift the vehicle. 2. Remove the torque converter access plug from the oil pan. 3. Install a J 44226 crankshaft balancer holder to the torque converter. 4. Install a new crankshaft balancer shim on to the crankshaft snout. Crankshaft balancer installer 5.
Page 55 5.3L & 6.0L Engines To Remove: 1. Remove the drive belt from the pulleys. 2. Remove the A/C drive belt from the pulleys. 3. Remove the cooling fan and starter from the engine. 4. Install a J 42386-A flywheel holding tool onto the flywheel. Torque the bolt to 37 ft- lb (50 Nm).
Page 56 To Install: 1. Use a J 41665 crankshaft balancer and sprocket installer to install the crankshaft balancer onto the crankshaft. 2. Install the old crankshaft balancer bolt into the crankshaft balancer. Tighten the bolt to 240 ft-lb (330 Nm). 3. Remove the old crankshaft balancer bolt from the crankshaft balancer. 4.
Page 57 Cylinder Head Removal & Installation 4.2L Engine To Remove: 1. Remove the air cleaner element from the air outlet duct. 2. Remove the drive belt from the pulleys. 3. Remove the air cleaner outlet resonator assembly, powertrain control module (PCM), generator, and intake manifold from the engine. 4.
Page 58 EN-48464 Installation 22. Install a EN-48464 lower timing gear tensioner holding tool between the timing chain and the crankshaft sprocket. Place it so that the narrow ramp of the wedge faces the timing chain. Seat the tool by taping it lightly with a plastic or brass hammer.
Page 59 Cylinder head bolt removal and installation 32. Remove and discard the bolts from the cylinder head.
Page 60 Cylinder head removal and installation 33. Remove the cylinder head from the engine block. 34. Set the cylinder head with the combustion chambers face up on a flat, clean surface. 35. Remove and discard the cylinder head gasket from the engine block. 36.
Page 61 To Install: 1. Place the new cylinder head gasket on the engine block. 2. Place the cylinder head on the engine block. Cylinder head bolt tightening sequence...
Page 62 1. Install cylinder head bolts 1 through 14 in sequence. Torque the bolts to 22 ft-lb (30 Nm). Use a J 45059 angle meter to turn the bolts, in sequence, an additional 155 degrees. 2. Install cylinder head bolts 16 and 17 in sequence. Torque the bolts to 62 in-lb (7 Nm).
Page 63 29. Attach the engine harness to the power steering pump and right front inner fender and set the harness aside. 30. Install the air cleaner outlet resonator assembly, powertrain control module (PCM), and generator onto the engine. 31. Install the drive belt onto the pulleys. 32.
Page 64 5.3L & 6.0L Engines Left Side To Remove: 1. Remove the generator and power steering pump from the engine. 2. Detach the generator bracket from the engine. 3. Drain the coolant from the engine. 4. Remove the coolant air bleed pipe from the engine. 5.
Page 65 To Install: 1. Install the locating pins and new cylinder head gasket on to the engine block. 2. Attach the cylinder head to the engine block. Cylinder head bolt tightening sequence 1. Torque the M11 bolts 1 through 10, in sequence to 22 ft-lb (30 Nm). Use a J 45059 angle meter to turn the bolts, in sequence, an additional 90 degrees.
Page 66 Right Side To Remove: 1. Remove the oil level indicator and tube from the cylinder head. 2. Drain the coolant from the engine. 3. Remove the coolant air bleed pipe from the engine. 4. Remove the right exhaust manifold from the cylinder head. 5.
Page 67 To Install: 1. Install the locating pins and new cylinder head gasket on to the engine block. 2. Attach the cylinder head to the engine block. Cylinder head bolt tightening sequence 3. Torque the M11 bolts 1 through 10, in sequence to 22 ft-lb (30 Nm). Use a J 45059 angle meter to turn the bolts, in sequence, an additional 90 degrees.
Page 68 Drive Belt Removal & Installation 4.2L Engine To Remove: 1. Install a 3/8 inch breaker bar onto the drive belt tensioner arm. 2. Turn the breaker bar clockwise until the tension on the drive belt is relieved. Drive belt removal and installation...
Page 69 3. Remove the drive belt from the pulleys 4. Turn the breaker bar counterclockwise to release the tensioner arm. To Install: 1. Install the drive belt onto all the pulleys except the drive belt tensioner pulley. 2. Install a 3/8 inch breaker bar onto the drive belt tensioner arm. 3.
Page 70 5.3L & 6.0L Engines To Remove: 1. Remove the air cleaner resonator outlet duct from the throttle body. 2. Install a hex-head socket breaker bar onto the drive belt tensioner. 3. Turn the breaker bar clockwise until the tension on the drive belt is relieved.
Page 71 4. Remove the drive belt from the generator pulley. 5. Turn the breaker bar counterclockwise to release the tensioner arm. 6. Remove the breaker bar from the tensioner. 7. Remove the drive belt from the remaining pulleys. To Install: 1. Install the drive belt onto all the pulleys except the generator pulley. 2.
Page 72 Drive Belt Tensioner Removal & Installation 4.2L Engine To Remove: 1. Remove the drive belt from the pulleys. Drive belt tensioner removal and installation 2. Detach the drive belt tensioner from the engine. To Install: 1. Attach the drive belt tensioner to the engine. Torque the bolt to 37 ft-lb (50 Nm). 2.
Page 73 5.3L & 6.0L Engines To Remove: 1. Remove the drive belt from the pulleys. accessory drive belt tensioner (5.3L, 6.0L) 2. Detach the drive belt tensioner from the engine. To Install: 1. Attach the drive belt tensioner to the engine. Torque the bolt to 37 ft-lb (50 Nm). 2.
Page 74 Engine Assembly Removal & Installation 4.2L Engine To Remove: 1. Remove the hood from the vehicle. 2. Disconnect the negative battery cable from the battery. 3. Drain the coolant from the engine. 4. Evacuate the refrigerant from the HVAC system. 5.
Page 75 Heater core hoses 18. Disconnect the heater hoses from the heater core. 19. Remove the secondary air injection (AIR) reaction solenoid valve from the engine. 20. engine lift bracket to the secondary air injection (AIR) port on the engine head. 21.
Page 76 Powertrain control module (PCM) removal and installation 27. Remove the powertrain control module (PCM) from the engine. 28. Detach the harnesses and front differential vent hose from the engine harness bracket. 29. Detach the engine harness bracket from the engine.
Page 77 Starter 30. Remove the positive battery cable and s-terminal lead from the starter. 31. Disconnect the A/C pressure sensor and A/C clutch connectors. 32. Remove the battery positive cable from the generator. 33. Disconnect the generator, knock sensor, crankshaft sensor, and camshaft sensor connectors.
Page 78 Engine grounds 34. Remove the grounds for the engine block on the left side. 35. Lift the vehicle. 36. Remove the left and right wheel drive shafts. 37. Remove the front propeller shaft from the transfer case. 38. Remove the engine protection shield from under the vehicle. 39.
Page 79 Transmission removal and installation 46. Remove the bolts from the top of the transmission bell housing. 47. Lift the transmission. 48. Install the transmission support to the frame, only using through bolts. 49. Remove the remaining bolts from the transmission bell housing. 50.
Page 80 To Install: 1. Remove the engine from the engine stand. 2. Slowly lower the engine into the engine compartment; make sure the engine brackets line up with the mounts. 3. Attach the secondary air injection (AIR) pipes to the back of the engine head. 4.
Page 81 42. the secondary air injection (AIR) reaction solenoid valve onto the engine. 43. Connect the heater hoses to the heater core. 44. Attach the power steering pump to the engine. Torque the bolts to 18 ft-lb (25 Nm). 45. Install the drive belt onto the pulleys. 46.
Page 82 5.3L & 6.0L Engines To Remove: 1. Remove the hood from the vehicle. 2. Cover both of the fenders. 3. Disconnect the negative battery cable from the battery. 4. Drain the coolant from the engine. 5. Evacuate the refrigerant from the HVAC system. 6.
Page 83 13. Disconnect the oil pressure sensor, heated oxygen sensor (HO2S) bank 1 sensor 1, heated oxygen sensor (HO2S) bank 2 sensor 1, and camshaft position (CMP) sensor connectors. 14. Remove the A/C compressor hose from the vehicle. 15. Detach the A/C compressor pipe from the engine and set aside. Engine coolant temperature sensor (ECT) connector...
Page 84 16. Disconnect the engine coolant temperature (ECT) sensor connector. 17. Detach the ground terminal from the engine near the engine coolant temperature (ECT) sensor. 18. Disconnect the A/C pressure switch connector. 19. Lift the vehicle. Engine grounds...
Page 85 20. Detach the lower ground terminals from the engine. 21. Remove the starter from the engine. 22. Detach the battery cable channel from the oil pan. 23. Disconnect the A/C compressor connector. 24. Lower the vehicle. 25. Move the engine harness to the side. 26.
Page 86 30. Remove the necessary ignition coils from the engine to attach a J 41798 engine lift bracket. 31. Attach a J 41798 engine lift bracket to the engine. Torque the M8 bolts to 18 ft-lb (25 Nm). Torque the M10 bolts to 37 ft-lb (50 Nm). 32.
Page 87 To Install: 1. Remove the J 21366 converter holding strap. 2. Remove the engine from the engine stand. 3. Lower the engine into the vehicle. 4. Mate the transmission to the engine. 5. Remove the transmission jack. 6. Install the upper transmission bolts and studs. Torque the bolts and studs to 37 ft- lb (50 Nm).
Page 88 36. For vehicles with 4WD, install the front differential drive axle to the vehicle. 37. Install the radiator support brace to the front of the vehicle. 38. Install the radiator into the vehicle. 39. Recharge the HVAC system with refrigerant. 40.
Page 89 Flywheel Removal & Installation 4.2L Engine To Remove: Flywheel removal and installation 1. Remove the transmission from the vehicle. 2. Detach the flywheel from the crankshaft.
Page 90 To Install: 1. Apply threadlock to the flywheel bolts. Flywheel bolt tightening sequence 2. Attach the flywheel to the crankshaft. Torque the bolts, in sequence, to 18 ft-lb (25 Nm). Use a J 36660-A torque angle meter to turn the bolts an additional 50 degrees.
Page 91 5.3L & 6.0L Engines To Remove: 1. Remove the transmission from the vehicle. Flywheel removal and installation 2. Mark the position of the flywheel to the crankshaft. 3. Detach the flywheel from the crankshaft.
Page 92 To Install: 1. Apply threadlock to the flywheel bolts. 2. Align the flywheel to the mark on the crankshaft. Flywheel bolt tightening sequence 3. Attach the flywheel to the crankshaft. Torque the bolts, in sequence, to 15 ft-lb (20 Nm). Torque the bolts again, in sequence, to 37 ft-lb (50 Nm). Torque the bolts a final time, in sequence, to 74 ft-lb (100 Nm).
Page 93 Drive Belt Idler Pulley Removal & Installation 4.2L Engine To Remove: 1. Remove the drive belt from the pulleys. 2. Lift the vehicle. 3. Remove the left front wheel from the vehicle. Drivebelt idler pulley removal and installation 4. Remove the bolts from the drive belt idler pulley through the left wheelhouse. 5.
Page 94 5.3L Engine To Remove: 1. Remove the drive belt from the pulleys. Idler pulley 2. Detach the drive belt idler pulley from the engine.
Page 95 To Install: 1. Attach the drive belt idler pulley to the engine. Torque the bolt to 37 ft-lb (50 Nm). 2. Install the drive belt onto the pulleys.
Page 96 Intake Manifold Removal & Installation CAUTION Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces 4.2L Engine To Remove:...
Page 97 3. Remove the throttle body and powertrain control module (PCM) from the engine. 4. Detach the fuel feed pipe from the fuel rail. 5. Detach the integral clip from the engine harness bracket. 6. Detach the engine harness bracket from the engine. 7.
Page 98 12. Detach the intake manifold from the engine. To Install: 1. Place a new intake manifold gasket onto the intake manifold. 2. Attach the intake manifold onto the engine. Torque the bolts to 89 in-lb (10 Nm). 3. Install the generator onto the engine. 4.
Page 99 10. Attach the fuel feed pipe to the fuel rail. 11. Install the powertrain control module (PCM) and throttle body onto the engine. 12. Connect the negative battery cable to the battery. 13. Check the fuel system for leaks by turning the ignition to on, with the engine off for 2 seconds.
Page 100 8. Remove the positive crankcase ventilation (PCV) hose from the engine. 9. Detach the heater water shutoff valve actuator inlet hose from the intake manifold. 10. Remove the evaporative emission (EVAP) purge solenoid vent tubes from the engine. 11. Detach the fuel feed pipe from the fuel rail. 12.
Page 101 15. Detach the intake manifold from the cylinder head. 16. Remove and discard the gaskets from the intake manifold. 17. Clean the sealing surfaces as necessary.
Page 102 To Install: 1. Install new gaskets onto the intake manifold. 2. Apply a 0.2 in (5 mm) bead of threadlock to the intake manifold bolts. Intake manifold bolt tightening sequence 3. Attach the intake manifold to the cylinder head. Torque the bolts, in sequence, to 44 in-lb (5 Nm).
Page 103 Removal & Installation 4.2L Engine To Remove: 1. Disconnect the negative battery cable from the battery. 2. Remove the bottom bolts from the A/C compressor. 3. Loosen the top bolt in the A/C compressor. 4. Remove the oil level indicator and tube from the engine. 5.
Page 104 12. Install two jack screws into the oil pan and tighten evenly to remove the oil pan from the engine. To Install: 1. Apply a 0.12 in (3 mm) bead of sealer to the oil pan sealing surface on the engine. NOTE: The oil pan must be installed no later than 10 minutes after applying the sealer.
Page 105 Oil pan removal and installation 12. Remove the remaining bolts from oil pan. 13. Remove the oil pan from the engine. 14. Remove the gasket from the oil pan by drilling out the rivets.
Page 106 To Install: NOTE: Make sure the oil pan is flush with the rear of the engine block when installing. 1. Apply a 0.2 in (5 mm) bead of sealant 0.8 in (20 mm) long to the front and rear tabs of the engine block that protrude into the oil pan surface.
Page 107 Oil Pump Removal & Installation 4.2L Engine To Remove: 1. Remove the engine front cover from the engine block. Oil pump cover 2. Detach the oil pump cover from the engine front cover. 3. Mark the position of the inner and the outer gears in relation to the oil pump housing.
Page 108 To Install: 1. Install the oil pump pressure relief valve, spring, and oil pump pressure relief valve plug. Torque the plug to 124 in-lb (14 Nm). 2. Align the marks on the inner and outer oil pump gears to the oil pump housing and install the gears.
Page 109 To Install: 1. Attach the oil pump to the engine block. Torque the bolts to 18 ft-lb (25 Nm). 2. Install the crankshaft oil deflector onto the engine block. 3. Use clean engine oil to lubricate the new oil pump screen o-ring and install it onto the screen.
Page 110 Crankshaft Rear Oil Seal Removal & Installation 4.2L Engine To Remove: 1. Remove the transmission from the engine. 2. Remove the flywheel from the crankshaft. Crankshaft rear oil seal removal 3. Use a suitable tool to pry the crankshaft rear oil seal from the housing. To Install: 1.
Page 111 5.3L & 6.0L Engines To Remove: 1. Remove the flywheel from the crankshaft. 2. Remove and discard the crankshaft rear oil seal from the rear cover. To Install: 1. Use clean engine oil to lubricate the outside diameter of the crankshaft rear oil seal and rear cover oil seal bore.
Page 112 Camshaft Cover Removal & Installation 4.2L Engine To Remove: 1. Remove the intake manifold from the engine. 2. Detach the A/C line bracket from the oil level indicator tube. 3. Detach the A/C line from the engine lift hook. 4. Set aside the A/C line. 5.
Page 113 9. Detach the camshaft cover from the cylinder head. 10. Remove and discard the camshaft cover seal from the cylinder head. To Install: 1. Place a new camshaft cover seal on the cylinder head. 2. Attach the camshaft cover to the cylinder head. Torque the bolts to 89 in-lb (10 Nm).
Page 114 Valve Rocker Arm Cover Removal & Installation 5.3L & 6.0L Engines Left Side To Remove: 1. If necessary, remove the intake manifold sight shield from the engine. 2. Disconnect the ignition coil harness connector. 3. Detach the engine harness from the engine and set aside. 4.
Page 115 7. Detach the valve rocker arm cover from the cylinder head. 8. Remove and discard the gasket from the valve rocker arm cover. 9. Clean the sealing surfaces as necessary. To Install: 1. Install a new gasket onto the valve rocker arm cover. 2.
Page 116 8. Detach the valve rocker arm cover from the cylinder head. 9. Remove and discard the gasket from the valve rocker arm cover. 10. Remove the oil fill tube from the valve rocker arm cover. 11. Remove the cap from the oil fill tube and discard the tube. 12.
Page 117 Valve Rocker Arm & Valve Lash Adjuster Removal & Installation 4.2L Engine To Remove: 1. Remove the camshaft cover from the cylinder head. 2. Turn the crankshaft until the valve of the desired cylinder is fully open. EN-47945 valve spring compressor 1.
Page 118 To Install: 1. Use oil to fill the valve lash adjuster and lubricate the valve rocker. 2. Install the valve lash adjuster into the cylinder head. 3. Install the valve rocker arm into the cylinder. 4. Turn the engine in the counterclockwise direction until the cam lobe is fully depressing the spring.
Page 119 Valve rocker arm pivot support 3. Remove the valve rocker arm pivot supports from the cylinder heads. 4. Remove the pushrods from the pivot supports. To Install: 1. Use clean engine oil to lubricate the valve rocker arms, pushrods, valve rocker arm flanges, and valve rocker arm bolts.
Page 120 Engine Front Cover Removal & Installation 4.2L Engine To Remove: 1. Drain the coolant from the engine. 2. Remove the cooling fan from the engine. 3. Remove the drive belt from the pulleys. 4. Remove the water pump from the engine. 5.
Page 121 10. Remove the bolts from the engine front cover, starting with the center. 11. Install jack screws into the threaded holes and tighten evenly. 12. Remove the engine front cover and jack screws from the engine. 13. Remove the oil pump from the engine front cover. 14.
Page 122 2. Apply a 0.12 in (3 mm) bead of sealer to the engine front cover in the areas marked above. 3. Align the oil pump with the splines on the crankshaft sprocket. 4. Place the engine front cover over the J 4219 cover alignment pins and loosely tighten the bolts.
Page 123 .3L & 6.0L Engines To Remove: 1. Remove the A/C compressor and bracket from the engine. 2. Remove the water pump from the engine. 3. Remove the crankshaft balancer from the crankshaft. Engine front cover removal and installation 4. Detach the engine front cover from the engine. 5.
Page 124 To Install: 1. Apply a 0.2 in (5 mm) bead of sealant 0.8 in (20 mm) long to the oil pan and engine block junction. 2. Place a new gasket on the engine front cover. 3. Attach the engine front cover to the engine, hand tighten the bolts. 4.
Page 125 Camshaft Timing Chain, Sprocket, and Tensioner Removal & Installation 4.2L Engine To Remove: 1. Remove the camshaft cover from the cylinder head. 2. Remove the engine front cover from the engine. 3. Move the timing chain tension shoe in to release the pressure on the chain. 4.
Page 126 Intake camshaft sprocket removal 6. Detach the intake camshaft sprocket from the intake camshaft. 7. Remove the timing chain from the sprockets. 8. Remove the crankshaft sprocket from the crankshaft. 9. Remove the access hole plugs from the cylinder head. 10.
Page 127 12. Detach the timing chain tensioner from the engine. To Install: 1. Attach the timing chain tensioner to the engine. Torque the bolts to 18 ft-lb (25 Nm). 2. Attach the timing chain tensioner guide to the engine. Torque the bolts to 89 in-lb (10 Nm).
Page 128 5. Install a J 44221 camshaft holding tool onto the camshafts. Make sure cylinder 1 is at top dead center and the camshaft flats are facing up. 6. Install the crankshaft sprocket onto the crankshaft. Timing chain alignment...
Page 129 7. Align the timing mark on the intake camshaft sprocket with the dark link on the timing chain. 8. Align the timing mark on the crankshaft sprocket with the dark link on the timing chain. 9. Attach the intake camshaft sprocket onto the intake camshaft, hand tighten the bolt.
Page 130 Removal & Installation 5.3L Engine To Remove: 1. Remove the oil pump from the engine. 2. Turn the crankshaft until the crankshaft and camshaft sprockets are aligned. Crankshaft sprocket removal and installation 3. Remove and discard the camshaft sprocket bolt. 4.
Page 131 Timing chain tensioner removal and installation 5. Detach the timing chain tensioner from the engine. Crankshaft sprocket removal...
Page 132 6. Use a J 41816-2 crankshaft end protector, a J 41558 crankshaft sprocket remover, bolts, and a J 8433 puller bar to remove the crankshaft sprocket from the camshaft. 7. Remove the crankshaft sprocket key from the crankshaft. To Install: 1.
Page 133: Engine Cooling
Engine Cooling WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. WARNING Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. Coolant Reservoir Removal &...
Page 134 Coolant Filling & Bleeding To Bleed: WARNING Do not remove the radiator cap or surge tank cap while the engine and radiator are hot. If the caps are removed while the engine and radiator are hot, scalding fluid and steam will be released under pressure.
Page 135 Cooling Fan & Shroud Removal & Installation To Remove: 1. Drain the coolant from the engine. 2. Remove the air cleaner assembly from the engine compartment. 3. Remove the air resonator assembly from the engine. 4. Remove the inlet radiator hose from the radiator. 5.
Page 136 Radiator Removal & Installation To Remove: 1. Drain the coolant from the radiator. 2. Lift the vehicle. 3. If equipped, remove the lower radiator support shield from the radiator. 4. Use a set of J 38185 hose clamp pliers to disconnect the outlet radiator hose from the radiator.
Page 137 To Install: 1. Attach the condenser onto the radiator. Torque the bolts to 21 ft-lb (28 Nm). 2. Install the radiator into the vehicle. 3. Lift the vehicle. 4. Use a set of J 38185 hose clamp pliers to connect the outlet radiator hose to the radiator.
Page 138 Engine Coolant Thermostat Removal & Installation 4.2L Engine To Remove: 1. Drain the coolant from the radiator. 2. Remove the generator from the engine. 3. Disconnect the outlet hose from the thermostat housing. Engine coolant thermostat removal and installation 4. Detach the thermostat housing from the engine block. 5.
Page 139 To Install: 1. Attach the thermostat housing to the engine block. Torque the bolts to 89 in-lb (10 Nm). 2. Use engine coolant to lubricate the inner diameter of the outlet hose. 3. Connect the outlet hose to the thermostat housing. 4.
Page 140 Water Pump Removal & Installation 4.2L Engine To Remove: 1. Drain the coolant from the engine. 2. Remove the fan from the engine 3. Remove the drive belt from the pulleys. Water pump pulley removal and installation 4. Use a J 41240 fan clutch remover and installer to secure the water pump pulley. 5.
Page 141 8. Detach the water pump from the engine. 9. Remove and discard the gasket from the water pump. To Install: 1. Install the new gasket onto the water pump. 2. Attach the water pump onto the engine. Torque the bolts to 35 in-lb (4 Nm). Torque the bolts again to 89 in-lb (10 Nm).
Page 142 5.3L & 6.0L Engines To Remove: 1. Drain the coolant from the engine. 2. Remove the air cleaner outlet duct from the engine compartment. 3. Remove the drive belt from the pulleys. 4. Remove the fan from the engine. 5. Use a set of J 38185 hose clamp pliers to disconnect the inlet hose from the water pump.
Page 143 7. Remove the nut from the auxiliary heater inlet and outlet hose/pipe. 8. Use a set of J 38185 hose clamp pliers to disconnect the hose from the throttle body. 9. Use a set of J 38185 hose clamp pliers to disconnect the auxiliary heater inlet and outlet hoses/pipes from the water pump.
Page 144: Engine Exhaust
Engine Exhaust WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Exhaust Manifold Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. 2. Detach the catalytic converter from the exhaust manifold. 3.
Page 145 5. Detach the exhaust manifold from the engine. 6. Remove and discard the gasket from the exhaust manifold. To Install: 1. Install a new gasket onto the exhaust manifold. 2. Apply threadlock GM P/N 12345493 to the exhaust manifold bolts. Exhaust manifold bolt tightening sequence 3.
Page 146 5.3L & 6.0L Engines Left Side To Remove: 1. Lift the vehicle. 2. Detach the catalytic converter from the exhaust manifold. 3. Lower the vehicle. 4. Remove the spark plugs from the cylinder head. 5. Detach the heat shield from the exhaust manifold. Left exhaust manifold removal and installation 6.
Page 147 3. Attach the exhaust manifold to the engine. The bolts should be tightened starting with the center two and working outward, from side to side. Torque the bolts in sequence to 11 ft-lb (15 Nm). Torque the bolts again, in sequence to 18 ft-lb (25 Nm).
Page 148 6. Detach the exhaust manifold from the engine. 7. Remove and discard the gasket from the exhaust manifold. To Install: 1. Install a new gasket onto the exhaust manifold. 2. Apply threadlock GM P/N 12345493 to the exhaust manifold bolts. 3.
Page 149 Catalytic Converter Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. 2. Remove the heated oxygen sensor (HO2S) from the catalytic converter. 3. Detach the catalytic converter from the exhaust manifold. 4. Remove and discard the seal from the catalytic converter. Muffler removal and installation 5.
Page 150 To Install: 1. Install the exhaust hanger onto the catalytic converter pipe. 2. Place the catalytic converter into the vehicle. 3. Install the transmission mount onto the frame. 4. Attach the catalytic converter to the muffler. Torque the bolts evenly to 33 ft-lb (45 Nm).
Page 151 7. Detach the catalytic converter from the muffler. 8. Remove the exhaust hanger insulators from the exhaust system and move the exhaust system rearward. 9. Detach the catalytic converter from the left and right exhaust manifolds. 10. Remove the catalytic converter from the vehicle. To Install: 1.
Page 152: Engine Reconditioning
Engine Reconditioning WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Determining Engine Condition There are a number of methods for evaluating the condition of the engine. A compression test can reveal the condition of the pistons, piston rings, cylinder bores, head gasket(s), valves and valve seats.
Page 153 Compression Test A noticeable lack of engine power, excessive oil consumption and/or poor fuel mileage measured over an extended period are all indicators of internal engine wear. Worn piston rings, scored or worn cylinder bores, blown head gaskets, sticking or burnt valves, and worn valve seats are all possible causes.
Page 154 13. Compare the highest readings from each cylinder to that of the others. The indicated compression pressures are considered within specifications if the lowest reading cylinder is within 75 percent of the pressure recorded for the highest reading cylinder. For example, if your highest reading cylinder pressure was 150 psi (1034 kPa), then 75 percent of that would be 113 psi (779 kPa).
Page 155 Overhaul Tips Aluminum has become extremely popular for use in engines, due to its weight savings. Observe the following precautions when handling aluminum parts: Never hot tank aluminum parts. The caustic hot tank solution will eat the aluminum Remove all aluminum parts (identification tag, etc.) from engine parts prior to tanking Always coat threads lightly with engine oil or anti-seize compounds before installation, to prevent seizure...
Page 156 Old gasket material and varnish or sludge can usually be removed using a scraper and/or cleaning solvent. Hard to remove deposits may require the use of a power drill with a wire brush. If using a wire brush, use extreme care around any critical machined surfaces (such as the gasket surfaces, bearing saddles, cylinder bores, etc.).
Page 157 Cleaning groove with an old ring CAUTION Minimize damage to the valve seats by removing carbon deposits before removing any valves from the cylinder heads. Choosing to de-carbonize the combustion chambers with the valves removed will increase the chances of damaging the valve seats.
Page 158 Repairing Damaged Threads Damaged bolt hole threads can be replaced with thread repair inserts Standard thread repair insert (left), and spark plug thread insert...
Page 159 Drill out the damaged threads with the specified size bit. Be sure to drill completely through the hole or to the bottom of a blind hole Using the kit, tap the hole in order to receive the thread insert. Keep the tap well oiled and back it out frequently to avoid clogging the threads...
Page 160 Screw the insert onto the installer tool until the tang engages the slot. Thread the insert into the hole until it is 1/4 - 1/2 turn below the top surface, then remove the tool and break off the tang using a punch Two types of thread repair inserts are usually supplied: a standard type for most -SAE coarse, SAE fine, metric course and metric fine thread sizes and a spark plug type to fit most spark plug port sizes.
Page 161 There are two basic types of cylinder heads used on today’s automobiles: the Overhead Valve (OHV) and the Overhead Camshaft (OHC). The latter can also be broken down into two subgroups: the Single Overhead Camshaft (SOHC) and the Dual Overhead Camshaft (DOHC).
Page 162 Disassembly OHV Heads 1. Remove the rocker arms and/or shafts. 2. Position the head so that the springs are easily accessed. Valve spring compressor tool 3. Use a valve spring compressor tool, and relieve spring tension from the retainer. A small magnet used in removal of valve locks...
Page 163 Valve locks (keepers) 5. Remove the valve locks from the valve tip and/or retainer. 6. Release the spring compressor and remove the valve spring. O-ring type seal...
Page 164 Umbrella/positive type seal 8. Remove the valve seal. Removing exhaust valve 9. Position the head to allow access for withdrawing the valve. 10. Remove the valve from the cylinder head. 11. If equipped, remove the valve spring cup.
Page 165 OHC Cylinder Heads Exploded view of a valve, seal, spring, retainer and locks from an OHC cylinder head Example of a multi-valve cylinder head with 2 intake and 2 exhaust valve ports...
Page 166 Cup Type Camshaft Followers Most cylinder heads with cup type camshaft followers will have the valve spring, retainer and locks recessed within the follower’s bore. You will need a C-clamp style valve spring compressor tool, an OHC spring removal tool (or its equivalent) as well as a small magnet to disassemble the head.
Page 167 2. Position the cylinder head to allow use of a C-clamp style valve spring compressor tool. OHC spring tool and C-clamp 3. Position the OHC spring removal adapter tool inside of the follower bore, then compress the valve spring using the C-clamp style valve spring compressor. 4.
Page 168 OHC shaft mounted rocker arms OHC rocker arm type head 1. Removed the rocker arms and/or shafts and the camshaft. 2. If applicable remove the hydraulic lash adjusters. Mark for reassembly.
Page 169 Remove the followers . . . then the camshaft can be removed by sliding it out (shown), or unbolting a bearing cap (not shown) 4. Position the cylinder head to allow access to the valve spring. 5. Use a valve spring compressor tool to relieve the spring tension from the retainer.
Page 170 Compressing the valve spring Removing the valve locks 7. Remove the valve locks from the valve tip and/or retainer. 8. Release the spring compressor and remove the valve spring off of the valve stem.
Page 171 Valve spring and retainer 9. Remove the valve seal. Removing valve seal from the guide. 10. Position the head to allow access for removing the valve.
Page 172 NOTE: Some cylinder heads may have mushroomed valve lock grooves and/or valve tips, making it difficult to remove valves. If so, use a metal file to carefully remove the high spots around the lock grooves and/or tip. File enough to make valve removal possible.
Page 173 Inspection Inspect the cylinder head components for wear and/or damage. Valves Inspect the heads of the valves first. Look closely at the head, margin and face for any cracks, excessive wear or burning. The margin is the best place to look for burning. It should have a squared edge with an even width all around the circumference of the valve.
Page 174 Use a micrometer to check the valve stem diameter Springs, Retainers & Valve Locks Perform a visual inspection for broken springs. Check the free length and squareness of each spring. If applicable, ensure to distinguish between intake and exhaust springs. Use a ruler and/or machinist’s square to measure the length.
Page 175 Spring free-length check Valve spring squareness check...
Page 176 Valve Guides Check the guides carefully and inspect them for any cracks, chips or breakage. Also if the guide is a removable style (as in most aluminum heads), check them for any looseness or evidence of movement. All of the guides should appear to be at the same height from the spring seat.
Page 177 Cylinder Head Surface Flatness Clean the gasket surface of the cylinder head. Check the head for flatness. Machinist’s straight edge and feeler gauge Diagonal check...
Page 178 Place a machinist’s straight edge across the gasket mating surface. Using feeler gauges, determine the clearance at the center of the machinist’s straight edge and across the cylinder head at several points. Check along the centerline and diagonally on the head surface.
Page 179 Lapping The Valves NOTE: Before lapping the valves to the seats ensure that all related parts are in acceptable condition. NOTE: Before any valve seat machining and/or lapping can be performed, the guides must be within factory recommended specifications. 1. Invert the cylinder head. 2.
Page 180 Knurling is a process in which metal is displaced and raised, thereby reducing clearance, providing a true center, and oil control. In some cases, a knurled valve guide will not stand up for more than a short time. Installing a guide insert involves machining the worn guide to accept a bronze insert. One style is the coil-type which is installed into a guide that has been threaded.
Page 181 Cylinder Head Surface If the cylinder head is warped, it must be machined flat. If the warpage is extremely severe, the head may need to be replaced. In some instances, it may be possible to straighten a warped head enough to allow machining. NOTE: Any overhead valve cylinder head that shows excessive warpage should have the camshaft bearing journals align bored after the cylinder head has been resurfaced.
Page 182 Assembly All cylinder head parts should be cleaned and arranged in their respective order to ease reassembly. OHV Engines 1. Lightly lubricate the valve stems and insert all of the valves into the cylinder head in their original locations. 2. Install any valve spring shims which were removed. 3.
Page 183 Rocker Arm Type Camshaft Followers 1. Lightly lubricate the valve stems and insert all of the valves into the cylinder head in their original locations. 2. Install any valve spring shims that were removed if using the original springs. 3. Install the new valve seals as follows: If the valve seal presses over the guide, lightly lubricate the outer guide surfaces.
Page 184: Engine Block
Engine Block General Information NOTE: Replace only the components that show signs of wear or are physically damaged. Disassembly Pushrod Engines Mount the engine on a suitable engine stand. Remove the pushrods and lifters. Remove the timing gears and/or timing chain assembly. Remove the oil pump drive assembly. Remove the camshaft from the engine block.
Page 185 CAUTION The sharp threads of the rod bolts/studs can score the crankshaft journal. Install rubber hose sections or plastic caps over the rod bolts when pushing the piston and connecting rod assembly out of the engine. Carefully tap the piston out of the bore using a wooden hammer handle or piston knocker Reposition the engine block, so that the number one cylinder bore (head surface) is facing up.
Page 186 Cylinder Ridge Removal NOTE: You must remove cylinder ridges before removing the piston and connecting rod assemblies. 1. Rotate the crankshaft until the piston is at the bottom of its travel. 2. Cover the head of the piston with a rag. 3.
Page 187 results of this inspection will determine whether the cylinder can be used in its existing size and condition, or a re-bore to the next oversize is required (or in the case of removable sleeves, have replacements installed). Measuring cylinder bore diameter Measurements are taken at three locations in each cylinder: at the top, middle and bottom.
Page 188 reflect the most wear. This is where the greatest force is exerted on the cylinder as the piston is forced down during combustion. This is known as thrust wear. Take the top, 90 degree measurement and compare it to the bottom, 90 degree measurement. The difference between them is the cylinder taper.
Page 189 Measuring the piston’s outer diameter Use a micrometer and measure the outside diameter of the piston perpendicular to the wrist pin at the skirt. Compare this measurement to the cylinder measurement obtained earlier. The difference between the two readings is the piston-to-wall clearance. If the clearance is within specifications, the piston may be used as is.
Page 190 Bearings All of the engine bearings including full circle ones used on most camshafts, auxiliary shafts and balance shafts should be visually inspected for wear and/or damage. The bearing should look evenly worn all around with no deep scores or pits. If the bearing is severely worn, scored, pitted or heat blued, then the bearing, and the components that use it, should be inspected.
Page 191 Refinishing If the cylinders are not to be re-bored, then the cylinder glaze can be removed with a ball hone. When removing cylinder glaze with a ball hone, use a light or penetrating type oil to lubricate the hone. Do not allow the hone to run dry as this may cause excessive scoring of the cylinder bores and wear on the hone.
Page 192 Front of piston mark...
Page 193 Assembly Mount the engine block onto the engine stand. Wash and dry the block including the cylinder bores, oil passages and crankshaft. Replace any freeze or oil galley plugs that were removed during disassembly. Crankshaft NOTE: The oil holes in the bearing inserts must be aligned with the oil holes in the cylinder block.
Page 194 Measuring bearing clearance gauging material If clearance exceeds specified limits, try a 0.001 in. or 0.002 in. undersize bearing in combination with the standard bearing. Bearing clearance must be within specified limits. If a standard and 0.002 in. undersize bearing does not bring clearance within desired limits, refinish crankshaft journal, and install undersize bearings.
Page 195 Use a dial gauge to check crankshaft end-play A. Mount a dial gauge to the engine block and position the tip of the gauge to read from the crankshaft end. B. Pry the crankshaft toward the rear of the engine and zero the gauge. Measuring crankshaft end-play...
Page 196 C. Pry the crankshaft toward the front of the engine and read the gauge. D. Confirm that the reading is within the specified range. E. If not, install a new thrust bearing and repeat the procedure. F. If the measurement remains out of the specified range after installing a new thrust bearing, inspect the thrust surfaces of the crankshaft, and if possible, repair it.
Page 197 2. Check the ring side clearance of the compression rings with a feeler gauge inserted between the ring and its lower land according to specification. The gauge should slide freely around the entire ring circumference without binding. Any wear that occurs will form a step at the inner portion of the lower land. If the lower lands have high steps, the piston should be replaced.
Page 198 Ring top side marks 5. Install the rings on the pistons. Install the oil control ring first, then the second compression ring and finally the top compression ring. Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage. Piston and rod assembly installation...
Page 199 6. Make sure the ring gaps are properly spaced around the circumference of the piston. Fit a piston ring compressor around the piston and slide the piston and connecting rod assembly down into the cylinder bore, pushing it in with the wooden hammer handle.
Page 200 Engine Start-Up & Break-In Starting the Engine 1. Fill the crankcase with the proper quantity and grade of engine oil. 2. Fill the cooling system with a 50/50 mixture of coolant/water. 3. Connect the vehicle battery. 4. Disable the ignition and crank the engine to develop oil pressure. Check the oil pressure indicator;...
Page 201 DRIVABILITY & EMISSIONS CONTROLS Precautions Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: Always wear safety goggles or some type of eye/face protection when working with, around or under a vehicle.
Page 202 CAUTION Many electronic components are considered to be "static sensitive". This means that their electronic components are vulnerable to damage from the natural static electricity that builds up on people and other objects if not properly discharged. In the event of static damage, components might fail immediately or might continue to operate, but suffer unexpected failure later.
Page 203 Emissions Controls System Overview General Information The first emissions controls implemented in the mid 1960s consisted of engine modifications and add on pollution control devices. These pollution control systems moderately lowered emissions, but they also caused a reduction in engine performance and increased fuel consumption.
Page 204 Emission Control Systems In order to help reduce emissions and improve fuel economy in the 1980s, manufacturers started equipping vehicles with three-way catalysts and electronic fuel metering systems. By 1988, the California Air Resources Board (CARB) began regulation of the OBD systems sold in California.
Page 205 The Clean Air Act Amendments of 1990 recognized the fact that vehicles with malfunctioning emissions control systems could go undetected for extended periods. Annual emissions inspection programs were not enough. The EPA required vehicle manufacturers to produce vehicle OBD systems capable of immediately identifying the vehicle operator of emissions faults, effective from 1996.
Page 206 Sulfur Oxides (SOx) Sulfur oxides consist of various amounts of oxygen and sulfur. Sulfur oxides result from the burning of lower grades of fossil fuels, such as coal or oil. Air Pollution The earth's atmosphere, at or near sea level, consists approximately of 78 percent nitrogen, 21 percent oxygen and 1 percent other gases.
Page 207 Working with Federal, State and Local mandated regulations and by carefully monitoring emissions, big business has greatly reduced the amount of pollutant introduced from its industrial sources, striving to obtain an acceptable level. Because of the mandated industrial emission clean up, many land areas and streams in and around the cities that were formerly barren of vegetation and life, have now begun to move back in the direction of nature's intended balance.
Page 208 movement with the inversion takes place to allow the smog layer to rise above ground level but the pollutants still cannot dissipate. This inversion can remain for days over an area, with the smog level only rising or lowering from ground level to a few hundred feet high.
Page 209 Automotive Emissions Before emission controls were mandated on internal combustion engines, other sources of engine pollutants were discovered along with the exhaust emissions. It was determined that engine combustion exhaust produced approximately 60 percent of the total emission pollutants, fuel evaporation from the fuel tank produced 20 percent, with the final 20 percent being produced through the crankcase as a by-product of the combustion process.
Page 210 Carbon Monoxide Carbon monoxide is formed when not enough oxygen is present during the combustion process to convert carbon (C) to carbon dioxide (CO ). An increase in the carbon monoxide (CO) emission is normally accompanied by an increase in the hydrocarbon (HC) emission because of the lack of oxygen to completely burn all of the fuel mixture.
Page 211 Although ozone at ground level can be harmful, ozone is beneficial to the earth's inhabitants. By having a concentrated ozone layer called the "ozonosphere,'' between 10 and 20 miles (16 - 32 km) up in the atmosphere, much of the ultra violet radiation from the sun's rays are absorbed and screened.
Page 212 their low flash or ignition temperature point. Such oils burn prematurely during the combustion process causing emission of particulate matter. The cooling system is an important factor in the reduction of particulate matter. The optimum combustion will occur, with the cooling system operating at a temperature specified by the manufacturer.
Page 213 Fuel pumped from an underground storage tank is cool but when exposed to a warmer ambient temperature, will expand. Before controls were mandated, an owner might fill the fuel tank with fuel from an underground storage tank and park the vehicle for some time in warm area, such as a parking lot.
Page 214: Electronic Engine Controls
Electronic Engine Controls WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information The Engine Management System (EMS) uses several different sensors and actuators to gather and control various emissions and driveability aspects of the vehicle. These may include but are not limited to: MAP –...
Page 215 evaporative pressure is being maintained in fuel tank. This is a test for gross evaporative emissions leaks. Vehicles with Canister Purge and Vent Valves Some vehicles will route a small amount of engine vacuum through the canister purge valve to the fuel tank. When both the canister purge valve and vent solenoid valve are closed the vacuum is trapped between the fuel tank and canister purge valve.
Page 216 CKP Sensor The crankshaft position (CKP) sensor generates a magnetic pulse signal when the engine is cranking or running. This signal is used by the powertrain control module (PCM) to detect the crankshaft position of each cylinder. Engine speed is a very important input to the PCM. Crankshaft speed and position are the basis for many calculations made by the computer.
Page 217 The Powertrain Control Module (PCM) uses the camshaft position sensor to manage sequential fuel injection and as part of misfire diagnosis. The PCM constantly monitors the number of pulses on the signal circuit. The PCM compares the number of camshaft sensor reference pulses and the number of crankshaft position sensor reference pulses received.
Page 218 Typical oxygen sensor The oxygen sensors on later model vehicles are equipped with a heater circuit. The heater circuit in the oxygen sensor shortens the time required for the sensor to reach operating temperature and provides a more accurate signal. IAT Sensor The Intake Air Temperature (IAT) sensor is variable temperature sensitive resistor that measures the temperature of the air in the intake system.
Page 219 sensor failure accompanies an Engine Coolant Temperature (ECT) sensor failure, cooling fan operation may also be affected. Some manufacturers incorporate the Intake Air Temperature (IAT) sensor as part of the Mass Air Flow (MAF) sensor (Air Flow Meter). Knock Sensor The purpose of the Knock Sensor (KS) is to monitor pre-ignition or "engine knock"...
Page 220 Typical TP sensor VSS Sensor The Vehicle Speed (VSS) Sensor input is used by the PCM to determine vehicle speed. The VSS generates a signal that increases in frequency proportionate to vehicle speed. The PCM has a base frequency stored in memory for a distance of one mile. By comparing the input and stored value, the PCM calculates vehicle speed.
Page 221 Typical VSS WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section.
Page 222 Evaporative Emission Canister Removal & Installation To Remove: 1. Remove the spare tire from the vehicle. 2. Lift the vehicle. 3. If equipped, remove the fuel tank shield from the frame. Evaporative emission canister...
Page 223 4. Disconnect the evaporative emission (EVAP) vapor pipe, purge pipe, and vent pipe from the evaporative emission (EVAP) canister. 5. Detach the evaporative emission (EVAP) canister and mounting bracket assembly from the vehicle. 6. Detach the evaporative emission (EVAP) canister from the mounting bracket. 7.
Page 224 Evaporative Emission Canister Purge Solenoid Valve Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. 2. Disconnect the evaporative emission (EVAP) canister purge solenoid valve connector. 3. Disconnect the evaporative emission (EVAP) purge pipe and engine vacuum pipe from the evaporative emission (EVAP) canister purge solenoid valve.
Page 225 1. Remove the evaporative emission (EVAP) canister purge solenoid valve from the mounting bracket. 2. If replacing the bracket, detach the bracket from the engine. To Install: 1. If replacing the bracket, attach the bracket to the engine. Torque the bolt to 89 in-lb (10 Nm).
Page 226 To Install: 1. Install the evaporative emission (EVAP) canister purge solenoid to the fuel rail. 2. Connect the evaporative emission (EVAP) canister purge solenoid connector. 3. Connect the evaporative emission (EVAP) pipes from the evaporative emission (EVAP) canister purge solenoid. 4.
Page 227 Evaporative Emission Canister Vent Solenoid Valve Removal & Installation To Remove: 1. Lift the vehicle. 2. Disconnect the evaporative emission (EVAP) canister vent solenoid valve connector. Evaporative emission canister vent solenoid valve removal and installation 3. Disconnect the evaporative emission (EVAP) vent pipe from the evaporative emission (EVAP) canister vent solenoid valve.
Page 228 Fuel Tank Pressure Sensor Removal & Installation To Remove: 1. Remove the fuel tank from the vehicle. 2. Disconnect the fuel tank pressure sensor connector. Fuel tank pressure sensor removal and installation 3. Remove the fuel tank pressure sensor from the fuel tank. 4.
Page 229 Positive Crankcase Ventilation Hoses Removal & Installation 4.2L Engine To Remove: 1. Disconnect the positive crankcase ventilation dirty air hose from the intake manifold and positive crankcase ventilation (PCV) orifice tube. 2. Loosen the clamps on the throttle body. 3. Disconnect the fuel pressure regulator vacuum supply hose from the air cleaner outlet resonator.
Page 230 Mass Airflow/Intake Air Temperature Sensor Removal & Installation 4.2L Engine To Remove: CAUTION Make sure not to dent, puncture, or damage the honeycell in the air inlet end of the mass airflow/intake air temperature sensor. Do not touch or allow anything to come into contact with the sensing elements of the mass airflow/intake air temperature sensor.
Page 231 Mass airflow/intake air temperature sensor 1. Disconnect the mass airflow/intake air temperature sensor connector. 2. Loosen the air cleaner outlet duct clamps at the mass airflow/intake air temperature sensor and throttle body. 3. Remove the air cleaner outlet duct bolt from the engine. 4.
Page 232 To Install: Arrow (A), Mass airflow/intake air temperature sensor 1. Install the mass airflow/intake air temperature sensor into the air cleaner housing with the arrow pointing toward the engine. 2. Torque the mass airflow/intake air temperature sensor clamp at the air cleaner housing to 62 in-lb (7 Nm).
Page 233 Camshaft Position Sensor Removal & Installation 4.2L Engine To Remove: 1. Disconnect the camshaft position (CMP) sensor connector. Camshaft position sensor 2. Detach the camshaft position (CMP) sensor from the engine.
Page 234 To Install: 1. Attach the camshaft position (CMP) sensor into the engine. Torque the bolt to 89 in-lb (10 Nm). 2. Connect the camshaft position (CMP) sensor connector. 5.3L Engine 2003-2004 To Remove: 1. Remove the intake manifold from the engine. 2.
Page 235 To Install: 1. Attach the camshaft position (CMP) sensor to the engine. Torque the bolt to 21 ft- lb (29 Nm). 2. Connect the camshaft position (CMP) sensor connector. 3. Install the intake manifold onto the engine. 5.3L & 6.0L Engines 2005-2007 To Remove: 1.
Page 236 To Install: 1. Connect the camshaft position sensor to the camshaft position sensor jumper harness. 2. Install the o-ring onto the camshaft position sensor. 3. Attach the camshaft position sensor assembly to the engine. Torque the bolts to 18 ft-lb (25 Nm). 4.
Page 237 Engine Coolant Temperature Sensor Removal & Installation 4.2L Engine To Remove: 1. Disconnect the negative battery cable from the battery. 2. Drain the coolant from the engine. 3. Disconnect the engine coolant temperature (ECT) sensor connector. Engine coolant temperature sensor removal and installation 4.
Page 238 5.3L & 6.0L Engines To Remove: 1. Drain the coolant from the engine. 2. Disconnect the engine coolant temperature (ECT) sensor connector. Engine coolant temperature sensor removal and installation 3. Remove the engine coolant temperature (ECT) sensor from the left cylinder head. To Install: 1.
Page 239 Crankshaft Position Sensor Removal & Installation To Remove: 4.2L Engine 1. Lift the vehicle. 2. Disconnect the crankshaft position (CKP) sensor connector. Crankshaft position sensor removal and installation 3. Detach the crankshaft position (CKP) sensor from the engine block. 4. If necessary, remove and discard the o-ring from the crankshaft position (CKP) sensor.
Page 240 5.3L & 6.0L Engines To Remove: 1. Remove the starter from the engine 2. Disconnect the crankshaft position (CKP) sensor connector. 3. Make sure the area around the crankshaft position (CKP) sensor is clean. Crankshaft position sensor 4. Detach the crankshaft position (CKP) sensor from the engine. To Install: 1.
Page 241 Powertrain Control Module (PCM) Removal & Installation CAUTION The control module is sensitive to static discharge. Make sure to touch a nearby metal object to discharge any static electricity that may be built up on your body. 4.2L Engine 2002-2005 NOTE: Make sure the ignition is in the off position when connector or disconnecting power to the powertrain control module (PCM).
Page 242 2. Detach the powertrain control module (PCM) connectors. 3. Remove the powertrain control module (PCM) retaining nuts and bolts from the intake manifold. 4. Remove the powertrain control module (PCM) from the intake manifold. 5. If replacing the mounting studs, remove the mounting studs from the intake manifold.
Page 243 Powertrain control module (PCM) removal and installation 3. Detach the powertrain control module (PCM) and bracket from the intake manifold. To Install: 1. Attach the powertrain control module (PCM) and bracket to the intake manifold. Torque the nuts and bolts to 80 in-lb (9 Nm). 2.
Page 244 Powertrain control module (PCM) 4. Remove the powertrain control module (PCM) from the bracket. 5. Detach the connectors from the powertrain control module (PCM). To Install: 1. Attach the connectors to the powertrain control module (PCM). Torque the bolts to 71 in-lb (8 Nm).
Page 245 Engine Control Module (ECM) Removal & Installation 5.3L & 6.0L Engines 2005-2007 NOTE: Make sure the ignition is in the off position when connector or disconnecting power to the powertrain control module (PCM). NOTE: Make sure to remove any debris from the powertrain control module (PCM) connector surfaces and inspect the gaskets.
Page 246 Engine control module (ECM) 6. Remove the engine control module (ECM) from the bracket. 7. If replacing the bracket, detach the transmission control module (TCM)/engine control module (ECM) bracket from the frame. To Install: 1. If replacing the bracket, attach the transmission control module (TCM)/engine control module (ECM) bracket to the frame.
Page 247 Knock Sensor (KS) Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. Knock sensor (KS) removal and installation 2. Disconnect the knock sensor (KS) connectors. 3. Detach the knock sensors (KS) from the engine block. To Install: 1. Attach the knock sensors (KS) to the engine block. Torque the sensor to 18 ft-lb (25 Nm).
Page 248 5.3L Engine 2003-2004 To Remove: 1. Remove the intake manifold from the engine. 2. Remove the knock sensor (KS) covers from the engine. 3. Disconnect the knock sensor (KS) connectors. Knock sensor (KS) removal and installation 4. Remove the knock sensors (KS) from the engine. To Install: 1.
Page 249 5.3L & 6.0L Engines 2005-2007 Left Side To Remove: Knock sensor (KS) 1 removal and installation 1. Disconnect the knock sensor (KS) 1 connector. 2. Detach knock sensor (KS) 1 from the left side of the engine block. To Install: 1.
Page 250 Right Side To Remove: Knock sensor (KS) 2 removal and installation 1. Disconnect the knock sensor (KS) 2 connector. 2. Detach knock sensor (KS) 2 from the right side of the engine block. To Install: 1. Attach knock sensor (KS) 2 to the right side of the engine block. Torque the bolt to 15 ft-lb (20 Nm).
Page 251 Manifold Absolute Pressure (MAP) Sensor Removal & Installation 4.2L Engine To Remove: 1. Disconnect the manifold absolute pressure (MAP) sensor connector. Manifold absolute pressure (MAP) sensor removal and installation 2. Detach the manifold absolute pressure (MAP) sensor from the intake manifold. 3.
Page 252 5.3L Engine To Remove: 1. If equipped, remove the intake manifold sight shield from the intake manifold. 2. Disconnect the manifold absolute pressure (MAP) sensor connector. Manifold absolute pressure (MAP) sensor removal and installation 3. Remove the manifold absolute pressure (MAP) sensor from the intake manifold. To Install: 1.
Page 253 Oil Pressure Switch Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. 2. Remove the engine shield from the frame. 3. Disconnect the oil pressure switch connector. Oil pressure sensor 4. Remove the oil pressure switch from the engine block. To Install: 1.
Page 254 Oil Pressure Sensor Removal & Installation 5.3L & 6.0L Engines To Remove: 1. Remove the intake manifold from the engine. 2. Disconnect the oil pressure sensor connector. Oil pressure sensor removal and installation 3. Use a J 41712 oil pressure sensor socket to remove the oil pressure sensor from the engine.
Page 255 Heated Oxygen Sensor Removal & Installation 4.2L Engine Sensor 1 To Remove: 1. Disconnect the heated oxygen sensor (HO2S) connector. Heated oxygen sensor (HO2S) 1 removal and installation 2. For 2002 through 2003 model years, use a J 39194-C oxygen sensor wrench to remove the heated oxygen sensor (HO2S) from the engine.
Page 256 To Install: 1. Apply an anti-seize compound to the heated oxygen sensor (HO2S) threads. 2. For 2002 through 2003 model years, use a J 39194-C oxygen sensor wrench to install the heated oxygen sensor (HO2S) into the engine. 3. For 2004 through 2007 model years, use a J 39194-B heated oxygen sensor wrench to install the heated oxygen sensor (HO2S) into the engine.
Page 257 3. Use a J 39194-B heated oxygen sensor wrench to remove the heated oxygen sensor (HO2S) from the engine. To Install: 1. Apply an anti-seize compound to the heated oxygen sensor (HO2S) threads. 2. Use a J 39194-B heated oxygen sensor wrench to install the heated oxygen sensor (HO2S) into the engine.
Page 258 Accelerator Pedal Position Sensor Removal & Installation To Remove: 1. Disconnect the accelerator pedal position (APP) sensor connector. Accelerator pedal position sensor 2. Detach accelerator pedal position (APP) sensor from the accelerator pedal. To Install: 1. Attach the accelerator pedal position (APP) sensor to the accelerator pedal. Torque the fasteners to 89 in-lb (10 Nm).
Page 259 Vehicle Speed Sensor Removal & Installation To Remove: 1. Disconnect the vehicle speed sensor connector. Vehicle speed sensor (A), Retaining bolt (B), O-ring (C) 2. Detach the vehicle speed sensor from the transfer case. 3. Remove the o-ring from the vehicle speed sensor. To Install: 1.
Page 260 Trouble Codes WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information Scan Tools All late-model vehicles utilize computers to monitor and control the functions of on-board systems. These modules are known by many names such as Engine Control Unit (ECU), Engine Control Module (ECM), Powertrain Control Module (PCM), Transmission Control Module (TCM) and Vehicle Control Module (VCM).
Page 261 Generic Codes DTC Description P0109 Manifold Absolute Pressure/Barometric Pressure Circuit Intermittent P0110 Intake Air Temperature Sensor 1 Circuit P0111 Intake Air Temperature Sensor 1 Circuit Range/Performance P0112 Intake Air Temperature Sensor 1 Circuit Low P0113 Intake Air Temperature Sensor 1 Circuit High P0114 Intake Air Temperature Sensor 1 Circuit Intermittent P0115 Engine Coolant Temperature Circuit P0116 Engine Coolant Temperature Circuit Range/Performance...
Page 262 P0155 O2 Sensor Heater Circuit - Bank 2 Sensor 1 P0156 O2 Sensor Circuit - Bank 2 Sensor 2 P0157 O2 Sensor Circuit Low Voltage - Bank 2 Sensor 2 P0158 O2 Sensor Circuit High Voltage - Bank 2 Sensor 2 P0159 O2 Sensor Circuit Slow Response - Bank 2 Sensor 2 P0160 O2 Sensor Circuit No Activity Detected - Bank 2 Sensor 2 P0161 O2 Sensor Heater Circuit Bank 2 Sensor 2...
Page 263 P0206 Injector Circuit/Open Cylinder 6 P0207 Injector Circuit/Open Cylinder 7 P0208 Injector Circuit/Open Cylinder 8 P0209 Injector Circuit/Open Cylinder 9 P0210 Injector Circuit/Open Cylinder 10 P0211 Injector Circuit/Open Cylinder 11 P0212 Injector Circuit/Open Cylinder 12 P0213 Cold Start Injector 1 P0214 Cold Start Injector 2 P0215 Engine Shutoff Solenoid P0216 Injector/Injection Timing Control Circuit...
Page 264 P0029 Exhaust Valve Control Solenoid Circuit Range/Performance Bank 2 P0030 HO2S Heater Control Circuit Bank 1 Sensor 1 P0031 HO2S Heater Control Circuit Low Bank 1 Sensor 1 P0032 HO2S Heater Control Circuit High Bank 1 Sensor 1 P0033 Turbo Charger Bypass Valve Control Circuit P0034 Turbo Charger Bypass Valve Control Circuit Low P0035 Turbo Charger Bypass Valve Control Circuit High P0036 HO2S Heater Control Circuit Bank 1 Sensor 2...
Page 265 P0080 Exhaust Valve Control Solenoid Circuit High Bank 1 P0081 Intake Valve Control Solenoid Circuit Bank 2 P0082 Intake Valve Control Solenoid Circuit Low Bank 2 P0083 Intake Valve Control Solenoid Circuit High Bank 2 P0084 Exhaust Valve Control Solenoid Circuit Bank 2 P0085 Exhaust Valve Control Solenoid Circuit Low Bank 2 P0086 Exhaust Valve Control Solenoid Circuit High Bank 2 P0087 Fuel Rail/System Pressure - Too Low...
Page 266 P0251 Injection Pump Fuel Metering Control "A" (Cam/Rotor/Injector) P0252 Injection Pump Fuel Metering Control "A" Range/Performance (Cam/Rotor/Injector) P0253 Injection Pump Fuel Metering Control "A" Low (Cam/Rotor/Injector) P0254 Injection Pump Fuel Metering Control "A" High (Cam/Rotor/Injector) P0255 Injection Pump Fuel Metering Control "A" Intermittent (Cam/Rotor/Injector) P0256 Injection Pump Fuel Metering Control "B"...
Page 267 P0302 Cylinder 2 Misfire Detected P0303 Cylinder 3 Misfire Detected P0304 Cylinder 4 Misfire Detected P0305 Cylinder 5 Misfire Detected P0306 Cylinder 6 Misfire Detected P0307 Cylinder 7 Misfire Detected P0308 Cylinder 8 Misfire Detected P0309 Cylinder 9 Misfire Detected P0310 Cylinder 10 Misfire Detected P0311 Cylinder 11 Misfire Detected P0312 Cylinder 12 Misfire Detected...
Page 268 P0353 Ignition Coil "C" Primary/Secondary Circuit P0354 Ignition Coil "D" Primary/Secondary Circuit P0355 Ignition Coil "E" Primary/Secondary Circuit P0356 Ignition Coil "F" Primary/Secondary Circuit P0357 Ignition Coil "G" Primary/Secondary Circuit P0358 Ignition Coil "H" Primary/Secondary Circuit P0359 Ignition Coil "I" Primary/Secondary Circuit P0360 Ignition Coil "J"...
Page 269 P0410 Secondary Air Injection System P0411 Secondary Air Injection System Incorrect Flow Detected P0412 Secondary Air Injection System Switching Valve "A" Circuit P0413 Secondary Air Injection System Switching Valve "A" Circuit Open P0414 Secondary Air Injection System Switching Valve "A" Circuit Shorted P0415 Secondary Air Injection System Switching Valve "B"...
Page 270 P0461 Fuel Level Sensor "A" Circuit Range/Performance P0462 Fuel Level Sensor "A" Circuit Low P0463 Fuel Level Sensor "A" Circuit High P0464 Fuel Level Sensor "A" Circuit Intermittent P0465 EVAP Purge Flow Sensor Circuit P0466 EVAP Purge Flow Sensor Circuit Range/Performance P0467 EVAP Purge Flow Sensor Circuit Low P0468 EVAP Purge Flow Sensor Circuit High P0469 EVAP Purge Flow Sensor Circuit Intermittent...
Page 271 P0512 Starter Request Circuit P0513 Incorrect Immobilizer Key P0514 Battery Temperature Sensor Circuit Range/Performance P0515 Battery Temperature Sensor Circuit P0516 Battery Temperature Sensor Circuit Low P0517 Battery Temperature Sensor Circuit High P0518 Idle Air Control Circuit Intermittent P0519 Idle Air Control System Performance P0520 Engine Oil Pressure Sensor/Switch Circuit P0521 Engine Oil Pressure Sensor/Switch Range/Performance P0522 Engine Oil Pressure Sensor/Switch Low Voltage...
Page 272 P0563 System Voltage High P0564 Cruise Control Multi-Function Input "A" Circuit P0565 Cruise Control On Signal P0566 Cruise Control Off Signal P0567 Cruise Control Resume Signal P0568 Cruise Control Set Signal P0569 Cruise Control Coast Signal P0570 Cruise Control Accelerate Signal P0571 Brake Switch "A"...
Page 273 P0614 ECM / TCM Incompatible P0615 Starter Relay Circuit P0616 Starter Relay Circuit Low P0617 Starter Relay Circuit High P0618 Alternative Fuel Control Module KAM Error P0619 Alternative Fuel Control Module RAM/ROM Error P0620 Generator Control Circuit P0621 Generator Lamp/L Terminal Circuit P0622 Generator Field/F Terminal Circuit P0623 Generator Lamp Control Circuit P0624 Fuel Cap Lamp Control Circuit...
Page 274 P0665 Intake Manifold Tuning Valve Control Circuit High Bank 2 a) P0666 PCM/ECM/TCM Internal Temperature Sensor Circuit P0667 PCM/ECM/TCM Internal Temperature Sensor Range/Performance P0668 PCM/ECM/TCM Internal Temperature Sensor Circuit Low P0669 PCM/ECM/TCM Internal Temperature Sensor Circuit High P0670 Glow Plug Module Control Circuit P0671 Cylinder 1 Glow Plug Circuit P0672 Cylinder 2 Glow Plug Circuit P0673 Cylinder 3 Glow Plug Circuit...
Page 275 P0716 Input/Turbine Speed Sensor "A" Circuit Range/Performance P0717 Input/Turbine Speed Sensor "A" Circuit No Signal P0718 Input/Turbine Speed Sensor "A" Circuit Intermittent P0719 Brake Switch "B" Circuit Low P0720 Output Speed Sensor Circuit P0721 Output Speed Sensor Circuit Range/Performance P0722 Output Speed Sensor Circuit No Signal P0723 Output Speed Sensor Circuit Intermittent P0724 Brake Switch "B"...
Page 276 P0767 Shift Solenoid "D" Stuck On P0768 Shift Solenoid "D" Electrical P0769 Shift Solenoid "D" Intermittent P0770 Shift Solenoid "E" P0771 Shift Solenoid "E" Performance or Stuck Off P0772 Shift Solenoid "E" Stuck On P0773 Shift Solenoid "E" Electrical P0774 Shift Solenoid "E" Intermittent P0775 Pressure Control Solenoid "B"...
Page 277 P0818 Driveline Disconnect Switch Input Circuit P0819 Up and Down Shift Switch to Transmission Range Correlation P0820 Gear Lever X-Y Position Sensor Circuit P0821 Gear Lever X Position Circuit P0822 Gear Lever Y Position Circuit P0823 Gear Lever X Position Circuit Intermittent P0824 Gear Lever Y Position Circuit Intermittent P0825 Gear Lever Push-Pull Switch (Shift Anticipate) P0826 Up and Down Shift Switch Circuit...
Page 278 P0869 Transmission Fluid Pressure High P0870 Transmission Fluid Pressure Sensor/Switch "C" Circuit P0871 Transmission Fluid Pressure Sensor/Switch "C" Circuit Range/Performance P0872 Transmission Fluid Pressure Sensor/Switch "C" Circuit Low P0873 Transmission Fluid Pressure Sensor/Switch "C" Circuit High P0874 Transmission Fluid Pressure Sensor/Switch "C" Circuit Intermittent P0875 Transmission Fluid Pressure Sensor/Switch "D"...
Page 279 P0920 Gear Shift Forward Actuator Circuit/Open P0921 Gear Shift Forward Actuator Circuit Range/Performance P0922 Gear Shift Forward Actuator Circuit Low P0923 Gear Shift Forward Actuator Circuit High P0924 Gear Shift Reverse Actuator Circuit/Open P0925 Gear Shift Reverse Actuator Circuit Range/Performance P0926 Gear Shift Reverse Actuator Circuit Low P0927 Gear Shift Reverse Actuator Circuit High P0928 Gear Shift Lock Solenoid Control Circuit/Open...
Page 280 P0971 Pressure Control Solenoid "C" Control Circuit High P0972 Shift Solenoid "A" Control Circuit Range/Performance P0973 Shift Solenoid "A" Control Circuit Low P0974 Shift Solenoid "A" Control Circuit High P0975 Shift Solenoid "B" Control Circuit Range/Performance P0976 Shift Solenoid "B" Control Circuit Low P0977 Shift Solenoid "B"...
Page 281 P0A22 Generator Torque Sensor Circuit P0A23 Generator Torque Sensor Circuit Range/Performance P0A24 Generator Torque Sensor Circuit Low P0A25 Generator Torque Sensor Circuit High P0A26 Generator Torque Sensor Circuit Intermittent P0A27 Battery Power Off Circuit P0A28 Battery Power Off Circuit Low P0A29 Battery Power Off Circuit High P2000 NOx Trap Efficiency Below Threshold Bank 1 P2001 NOx Trap Efficiency Below Threshold Bank 2...
Page 282 P2039 Reductant Injection Air Pressure Sensor Circuit Low Input P2040 Reductant Injection Air Pressure Sensor Circuit High Input P2041 Reductant Injection Air Pressure Sensor Circuit Intermittent P2042 Reductant Temperature Sensor Circuit P2043 Reductant Temperature Sensor Circuit Range/Performance P2044 Reductant Temperature Sensor Circuit Low Input P2045 Reductant Temperature Sensor Circuit High Input P2046 Reductant Temperature Sensor Circuit Intermittent P2047 Reductant Injector Circuit/Open Bank 1 Unit 1...
Page 283 P2092 1) "A" Camshaft Position Actuator Control Circuit Low Bank 2 b) P2093 1) "A" Camshaft Position Actuator Control Circuit High Bank 2 b) P2094 1) "B" Camshaft Position Actuator Control Circuit Low Bank 2 c) P2095 1) "B" Camshaft Position Actuator Control Circuit High Bank 2 c) P2096 Post Catalyst Fuel Trim System Too Lean Bank 1 P2097 Post Catalyst Fuel Trim System Too Rich Bank 1 P2098 Post Catalyst Fuel Trim System Too Lean Bank 2...
Page 284 P2143 Exhaust Gas Recirculation Vent Control Circuit/Open P2144 Exhaust Gas Recirculation Vent Control Circuit Low P2145 Exhaust Gas Recirculation Vent Control Circuit High P2146 Fuel Injector Group "A" Supply Voltage Circuit/Open P2147 Fuel Injector Group "A" Supply Voltage Circuit Low P2148 Fuel Injector Group "A"...
Page 285 P2194 System Too Rich at Higher Load Bank 2 P2195 O2 Sensor Signal Stuck Lean Bank 1 Sensor 1 P2196 O2 Sensor Signal Stuck Rich Bank 1 Sensor 1 P2197 O2 Sensor Signal Stuck Lean Bank 2 Sensor 1 P2198 O2 Sensor Signal Stuck Rich Bank 2 Sensor 1 P2199 Intake Air Temperature Sensor 1 / 2 Correlation P2200 NOx Sensor Circuit Bank 1 P2201 NOx Sensor Circuit Range/Performance Bank 1...
Page 286 P2245 O2 Sensor Reference Voltage Circuit Low Bank 1 Sensor 1 P2246 O2 Sensor Reference Voltage Circuit High Bank 1 Sensor 1 P2247 O2 Sensor Reference Voltage Circuit/Open Bank 2 Sensor 1 P2248 O2 Sensor Reference Voltage Performance Bank 2 Sensor 1 P2249 O2 Sensor Reference Voltage Circuit Low Bank 2 Sensor 1 P2250 O2 Sensor Reference Voltage Circuit High Bank 2 Sensor 1 P2251 O2 Sensor Negative Current Control Circuit/Open Bank 1 Sensor 1...
Page 287 P2296 Fuel Pressure Regulator 2 Control Circuit High P2297 O2 Sensor Out of Range During Deceleration Bank 1 Sensor 1 P2298 O2 Sensor Out of Range During Deceleration Bank 2 Sensor 1 P2299 Brake Pedal Position / Accelerator Pedal Position Incompatible P2300 Ignition Coil "A"...
Page 288 P2347 Cylinder #12 Above Knock Threshold P2400 Evaporative Emission System Leak Detection Pump Control Circuit/Open P2401 Evaporative Emission System Leak Detection Pump Control Circuit Low P2402 Evaporative Emission System Leak Detection Pump Control Circuit High P2403 Evaporative Emission System Leak Detection Pump Sense Circuit/Open P2404 Evaporative Emission System Leak Detection Pump Sense Circuit Range/Performance P2405 Evaporative Emission System Leak Detection Pump Sense Circuit Low...
Page 289 P2444 Secondary Air Injection System Pump Stuck On Bank 1 P2445 Secondary Air Injection System Pump Stuck Off Bank 1 P2446 Secondary Air Injection System Pump Stuck On Bank 2 P2447 Secondary Air Injection System Pump Stuck Off Bank 2 P2500 Generator Lamp/L-Terminal Circuit Low P2501 Generator Lamp/L-Terminal Circuit High P2502 Charging System Voltage...
Page 290 P2547 Torque Management Request Input Signal "A" High P2548 Torque Management Request Input Signal "B" P2549 Torque Management Request Input Signal "B" Range/Performance P2550 Torque Management Request Input Signal "B" Low P2551 Torque Management Request Input Signal "B" High P2552 Throttle/Fuel Inhibit Circuit P2553 Throttle/Fuel Inhibit Circuit Range/Performance P2554 Throttle/Fuel Inhibit Circuit Low P2555 Throttle/Fuel Inhibit Circuit High...
Page 291 P2620 Throttle Position Output Circuit/Open P2621 Throttle Position Output Circuit Low P2622 Throttle Position Output Circuit High P2623 Injector Control Pressure Regulator Circuit/Open P2624 Injector Control Pressure Regulator Circuit Low P2625 Injector Control Pressure Regulator Circuit High P2626 O2 Sensor Pumping Current Trim Circuit/Open Bank 1 Sensor 1 P2627 O2 Sensor Pumping Current Trim Circuit Low Bank 1 Sensor 1 P2628 O2 Sensor Pumping Current Trim Circuit High Bank 1 Sensor 1 P2629 O2 Sensor Pumping Current Trim Circuit/Open Bank 2 Sensor 1...
Page 292 P2671 Actuator Supply Voltage "B" Circuit High P2700 Transmission Friction Element "A" Apply Time Range/Performance P2701 Transmission Friction Element "B" Apply Time Range/Performance P2702 Transmission Friction Element "C" Apply Time Range/Performance P2703 Transmission Friction Element "D" Apply Time Range/Performance P2704 Transmission Friction Element "E" Apply Time Range/Performance P2705 Transmission Friction Element "F"...
Page 293 P2750 Intermediate Shaft Speed Sensor "C" Circuit Range/Performance P2751 Intermediate Shaft Speed Sensor "C" Circuit No Signal P2752 Intermediate Shaft Speed Sensor "C" Circuit Intermittent P2753 Transmission Fluid Cooler Control Circuit/Open P2754 Transmission Fluid Cooler Control Circuit Low P2755 Transmission Fluid Cooler Control Circuit High P2756 Torque Converter Clutch Pressure Control Solenoid P2757 Torque Converter Clutch Pressure Control Solenoid Control Circuit Performance or Stuck Off...
Page 294 P2A03 O2 Sensor Circuit Range/Performance Bank 2 Sensor 1 P2A04 O2 Sensor Circuit Range/Performance Bank 2 Sensor 2 P2A05 O2 Sensor Circuit Range/Performance Bank 2 Sensor 3 P3400 Cylinder Deactivation System Bank 1 P3401 Cylinder 1 Deactivation/Intake Valve Control Circuit/Open P3402 Cylinder 1 Deactivation/Intake Valve Control Performance P3403 Cylinder 1 Deactivation/Intake Valve Control Circuit Low P3404 Cylinder 1 Deactivation/Intake Valve Control Circuit High...
Page 295 P3448 Cylinder 6 Exhaust Valve Control Circuit High P3449 Cylinder 7 Deactivation/Intake Valve Control Circuit/Open P3450 Cylinder 7 Deactivation/Intake Valve Control Performance P3451 Cylinder 7 Deactivation/Intake Valve Control Circuit Low P3452 Cylinder 7 Deactivation/Intake Valve Control Circuit High P3453 Cylinder 7 Exhaust Valve Control Circuit/Open P3454 Cylinder 7 Exhaust Valve Control Performance P3455 Cylinder 7 Exhaust Valve Control Circuit Low P3456 Cylinder 7 Exhaust Valve Control Circuit High...
Page 296 U0002 High Speed CAN Communication Bus Performance U0003 High Speed CAN Communication Bus (+) Open U0004 High Speed CAN Communication Bus (+) Low U0005 High Speed CAN Communication Bus (+) High U0006 High Speed CAN Communication Bus (–) Open U0007 High Speed CAN Communication Bus (–) Low U0008 High Speed CAN Communication Bus (–) High U0009 High Speed CAN Communication Bus (–) shorted to Bus (+) U0010 Medium Speed CAN Communication Bus...
Page 297 U0053 Vehicle Communication Bus C (–) High U0054 Vehicle Communication Bus C (–) shorted to Bus C (+) U0055 Vehicle Communication Bus D U0056 Vehicle Communication Bus D Performance U0057 Vehicle Communication Bus D (+) Open U0058 Vehicle Communication Bus D (+) Low U0059 Vehicle Communication Bus D (+) High U0060 Vehicle Communication Bus D (–) Open U0061 Vehicle Communication Bus D (–) Low...
Page 298 U0104 Lost Communication With Cruise Control Module U0105 Lost Communication With Fuel Injector Control Module U0106 Lost Communication With Glow Plug Control Module U0107 Lost Communication With Throttle Actuator Control Module U0108 Lost Communication With Alternative Fuel Control Module U0109 Lost Communication With Fuel Pump Control Module U0110 Lost Communication With Drive Motor Control Module U0111 Lost Communication With Battery Energy Control Module "A"...
Page 299 U0155 Lost Communication With Instrument Panel Cluster (IPC) Control Module U0156 Lost Communication With Information Center "A" U0157 Lost Communication With Information Center "B" U0158 Lost Communication With Head Up Display U0159 Lost Communication With Parking Assist Control Module U0160 Lost Communication With Audible Alert Control Module U0161 Lost Communication With Compass Module U0162 Lost Communication With Navigation Display Module U0163 Lost Communication With Navigation Control Module...
Page 300 U0206 Lost Communication With Folding Top Control Module U0207 Lost Communication With Moveable Roof Control Module U0208 Lost Communication With "Seat Control Module A" U0209 Lost Communication With "Seat Control Module B" U0210 Lost Communication With "Seat Control Module C" U0211 Lost Communication With "Seat Control Module D"...
Page 301 U0321 Software Incompatibility with Ride Level Control Module U0322 Software Incompatibility with Body Control Module U0323 Software Incompatibility with Instrument Panel Control Module U0324 Software Incompatibility with HVAC Control Module U0325 Software Incompatibility with Auxiliary Heater Control Module U0326 Software Incompatibility with Vehicle Immobilizer Control Module U0327 Software Incompatibility with Vehicle Security Control Module U0328 Software Incompatibility with Steering Angle Sensor Module U0329 Software Incompatibility with Steering Column Control Module...
Page 302: Fuel System
FUEL SYSTEM Service Precautions Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.
Page 303 Fuel Injection WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information Electronic fuel injectors for all gasoline engine applications are basically the same. They consist of an injector body, an electric solenoid, spring, nozzle and a filter. The injector is supplied a constant supply of pressurized fuel from the fuel system.
Page 304 Fuel Lines and Fittings Removal & Installation Quick Connect Fitting(S) Service (Metal Collar) To Remove: 1. Relieve the pressure in the fuel system. Quick connect retainer 2. Detach the retainer from the fitting. CAUTION When using compressed air, be sure to wear safety glasses. 3.
Page 305 4. Use a J 37088-A fuel line disconnect tool to release the locking tabs by inserting it into the female connector and pushing in. 5. Pull the male side of the connection from the female. 6. Wipe off the male pipe end with a clean shop towel. 7.
Page 306 Bartholomew 3. For Bartholomew connectors, squeeze the plastic release tabs. Q release 4. For Q release connectors, push the tab to the other end of the slot to release the fitting. Squeeze to release 5. For squeeze to release connectors, squeeze the plastic ring where shown.
Page 307 Sliding retainer 6. For sliding retainer connectors, push in on the side of the release tab. If the tab does not move, push in on the other side. Push down TI connector 7. For push down TI connector, press down on the tab where shown. 8.
Page 308 Fuel Injectors Testing WARNING Stay clear of all moving engine parts. Do not wear dangling jewelry or loose clothes. Keep power tool cords or other items that might get caught in a moving part away from fan and pulleys. Also, do not work on an open fuel system around open flames, welders, or any device that can cause a spark.
Page 309 One or More Injectors Are Not Clicking Unplug the fuel injector connector Probe the two terminals of a fuel injector to check resistance...
Page 310 Plug the correct "noid" light directly into the injector harness connector If the correct "noid" light flashes while the engine is running, the injector driver circuit inside the PCM is working If one or more injectors are found to be inoperative, testing the injector driver circuit and computer can be accomplished using a "noid"...
Page 311 test, then plug the "noid" light into the injector connector. Start the engine and the "noid" light should flash, signaling that the injector driver circuit is working. If the "noid" light flashes, but the injector does not click when plugged in, test the injector’s resistance. Resistance should be between 13.8-15.2 Ohms.
Page 312 Removal & Installation 4.2L Engine To Remove: WARNING Be careful when removing the fuel injectors in order to prevent damage to the connector pins and nozzles. Submerging the injectors in any cleaners or solvents may damage the injectors. CAUTION Fuel injector leakage may contaminate the engine oil. Fuel injector removal and installation...
Page 313 1. Remove the fuel rail assembly from the cylinder head. 2. Disconnect the fuel injector connectors. 3. Remove and discard the fuel injector retainer clips from the fuel injectors 4. Remove the fuel injectors from the fuel rail. 5. Remove and discard the fuel injector o-ring seals. To Install: Fuel injector (A), Part number (B), Build date code (C), Month (D), Day (E), Year (F), Shift (G)
Page 314 To Remove: WARNING Be careful when removing the fuel injectors in order to prevent damage to the connector pins and nozzles. Submerging the injectors in any cleaners or solvents may damage the injectors. CAUTION Fuel injector leakage may contaminate the engine oil. Fuel injector removal and installation 1.
Page 315 To Install: Fuel injector (A), Part number (B), Build date code (C), Month (D), Day (E), Year (F), Shift (G) NOTE: Use the correct part number when ordering new fuel injectors. 1. Use clean engine oil to lubricate the new o-ring seals. 2.
Page 316 Fuel Rail Assembly Removal & Installation 4.2L Engine To Remove: 1. Relieve the pressure in the fuel system. 2. Remove the intake manifold from the engine. 3. Disconnect the fuel feed pipe from the fuel rail. 4. Use GM X-30A or an equivalent spray type cleaner to clean the fuel rail assembly and cylinder head.
Page 317 1. Detach the fuel rail assembly from the cylinder head. 2. Remove and discard the lower o-ring seals from the fuel injectors. To Install: 1. Use clean engine oil to lubricate the new o-ring seals. 2. Install the o-ring seals onto the fuel injectors. 3.
Page 318 Fuel rail assembly removal and installation 13. Remove the fuel rail assembly bolts from the cylinder heads. 14. Loosen the fuel rail crossover pipe retainer clip screws. 15. Remove the fuel rail assemblies from the cylinder heads. 16. To avoid system contamination, plug the holes and cap the fittings. 17.
Page 319 To Install: 1. Use clean engine oil to lubricate the new o-ring seals. 2. Install the new lower o-ring seals onto the fuel injectors. 3. Install the fuel rail assemblies onto the cylinder heads. 4. Apply GM P/N 12345382 threadlock or equivalent to the fuel rail bolt threads. 5.
Page 320 Fuel Filter Removal & Installation 2002-2004 To Remove: NOTE: If a fuel filter is restricted, clean and inspect the inside of the fuel tank. 1. Relieve the pressure in the fuel system. 2. Lift the vehicle. 3. If necessary, remove the fuel tank shield from the frame. 4.
Page 321 To Install: 1. Install the fuel filter into the fuel filter bracket. 2. For vehicles with a 4.2L engine, install the screw into the fuel filter bracket. Torque the screw to 13 in-lb (1.5 Nm). 3. For vehicles with a 5.3L engine, install the screw into the fuel filter bracket. Torque the screw to 106 in-lb (12 Nm).
Page 322 Fuel Pressure Regulator Removal & Installation 4.2L Engine 2002-2004 To Remove: 1. Relieve the pressure in the fuel system. 2. Remove the air cleaner outlet resonator from the engine. 3. Detach the engine harness from the front of the engine. 4.
Page 323 1. Relieve the pressure in the fuel system. 2. Disconnect the fuel pressure regulator vacuum line from the fuel pressure regulator. 3. Make sure the fuel pressure regulator and surrounding areas are free from dirt and debris. 4. Remove and discard the fuel pressure regulator retainer from the fuel pressure regulator.
Page 324 Fuel Sender Assembly Removal & Installation To Remove: 1. Remove the fuel tank from the vehicle. 2. Use a J 45722 fuel tank sending unit wrench and a long breaker bar to turn the fuel sender lock ring counterclockwise. CAUTION Handling the fuel sender assembly by the fuel pipes may cause damage to the joints.
Page 325 1. Remove the fuel sender assembly from the fuel tank. 2. Remove and discard the fuel sender assembly seal from the fuel tank. 3. Drain the fuel from the fuel sender assembly into an appropriate container. 4. Clean the sealing surfaces as necessary. 5.
Page 326 Fuel System Pressure Relieving Fuel System Pressure 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the fuel filler cap from the filler neck. 4. Remove the appearance cover from the fuel supply manifold. 5.
Page 327 Fuel System Pressure Test 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the injector cover. 3. Connect a suitable fuel pressure gauge to the fuel supply line. Wrap a shop towel around the fitting while connecting the gauge to prevent fuel spillage.
Page 328 Fuel Tank Removal & Installation 2002-2004 To Remove: 1. Relieve the pressure in the fuel system. 2. Lift the vehicle. 3. Remove the frame brace from the frame. 4. Remove the fuel tank shield from the fuel tank. 5. Drain the fuel from the tank into an approved container. 6.
Page 329 1. Disconnect the evaporative emission (EVAP) vapor and vent valve pipes from the evaporative emission (EVAP) canister. 2. Disconnect the fuel return and feed pipes from the fuel tank. 3. To avoid system contamination, cap the evaporative emission (EVAP) and fuel pipes.
Page 330 6. Connect the evaporative emission (EVAP) vent valve and fuel tank pressure sensor connectors. 7. Connect the fuel hose to the fuel tank. Torque the clamp to 22 in-lb (2.5 Nm). 8. Connect the fuel return and feed pipes to the fuel tank. 9.
Page 331 6. Disconnect the evaporative emission (EVAP) canister fresh air, solenoid, and purge pipes from the evaporative emission (EVAP) canister. 7. Disconnect the fuel filler pipe recirculation hose from the fuel tank. 8. Loosen the fuel fill pipe clamp and disconnect the pipe from the fuel tank. 9.
Page 332 To Install: 1. Place the fuel tank under the vehicle. 2. Connect the evaporative emission (EVAP) vent valve, fuel tank pressure sensor, and fuel sender connectors. 3. Lift the fuel tank. 4. Attach the fuel tank straps to the frame. Torque the screws to 24 ft-lb (32 Nm). 5.
Page 333 Throttle Body Removal & Installation 4.2L Engine To Remove: 1. Remove the air cleaner outlet resonator from engine. 2. Disconnect the evaporative emission (EVAP) canister purge line from the throttle body. 3. Disconnect the throttle body connector. Throttle body removal and installation 4.
Page 334 To Install: 1. Apply GM P/N 12346004 sealer the throttle body bolts. 2. Attach the throttle body with the gasket to the intake manifold. Torque the bolts to 89 in-lb (10 Nm). 3. Connect the throttle body connector. 4. Connect the evaporative emission (EVAP) canister purge line to the throttle body. 5.
Page 335 5. Detach the throttle body from the intake manifold. 6. Remove and discard the gasket from the throttle body. To Install: 1. Install a new throttle body gasket to the throttle body. 2. For 2002-2004, attach the throttle body to the intake manifold. Torque the bolts to 89 in-lb (10 Nm).
Page 336: Chassis Electrical
CHASSIS ELECTRICAL Precautions Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: Always wear safety goggles or some type of eye/face protection when working with, around or under a vehicle.
Page 337 Supplemental Inflatable Restraint (SIR) System Service Precautions WARNING Work on these (SIR) systems should be performed by qualified service technicians. WARNING When performing service on or near the SIR components or the SIR wiring, you must disable the SIR system. Refer to Disarming & Arming for the disable/enable procedure. Failure to follow the correct procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.
Page 338 Basic Electricity WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Basic Electrical Theory Electricity is based on the principle that electrons are attracted to protons. Electron movement can be created when the atomic structure of a material is forced to become imbalanced.
Page 339 valence ring. Insulators are elements that contain between five and eight valence ring electrons. Semi-conductors are elements that contain four electrons in their valence ring. Impedance is something that restricts flow. If you put a number of connections along an electrical circuit, each connection becomes a source of resistance slowing the flow of electricity to its final destination.
Page 340 reason, the flow of current through the circuit is interrupted, the component fed by that circuit will cease to function properly. Perhaps the easiest way to visualize a circuit is to think of connecting a light bulb (with two wires attached to it) to the battery-one wire attached to the negative (–) terminal of the battery and the other wire to the positive (+) terminal.
Page 341 which receive power from a single circuit. This lessens the amount of wire needed to power components on the vehicle. How Does Electricity Work: The Water Analogy Electricity is the flow of electrons-the subatomic particles that constitute the outer shell of an atom.
Page 342 trait of lower resistance with higher temperatures (negative temperature coefficient). These principles are used in many of the sensors on the engine. Ohm's Law There is a direct relationship between current, voltage and resistance. The relationship between current, voltage and resistance can be summed up by a statement known as Ohm's law.
Page 343 Electrical Components Power Source Power is supplied to the vehicle by two devices: The battery and the alternator. The battery supplies electrical power during starting or during periods when the current demand of the vehicle’s electrical system exceeds the output capacity of the alternator. The alternator supplies electrical current when the engine is running.
Page 344 Protective Devices It is possible for large surges of current to pass through the electrical system of the vehicle. If this surge of current were to reach the load in the circuit, the surge could burn it out or severely damage it. It can also overload the wiring, causing the harness to get hot and melt the insulation.
Page 345 Switches & Relays Switches are used in electrical circuits to control the passage of current. The most common use is to open and close circuits between the battery and the various electric devices in the system. Switches are rated according to the amount of amperage they can handle.
Page 346 may use relays are the horn, headlights, starter, electric fuel pump and other high draw circuits. The internal components of a relay consist of a coil and a switch. These two components are linked together so that when one operates, the other operates at the same time. The large wires in the circuit are connected from the battery to one side of the relay switch (B+) and from the opposite side of the relay switch to the load (component).
Page 347 Wiring & Harnesses The average vehicle contains many feet of wiring, with hundreds of individual connections. To protect the many wires from damage and to keep them from becoming a confusing tangle, they are organized into bundles, enclosed in plastic or taped together and called wiring harnesses.
Page 348 Connectors Three types of connectors are commonly used in automotive applications-weatherproof, molded and hard shell. Weatherproof connector Weatherproof-these connectors are most commonly used where the connector is exposed to the elements. Terminals are protected against moisture and dirt by sealing rings which provide a watertight seal. All repairs require the use of a special terminal and the tool required to service it.
Page 349 Hard shell (left) and weatherproof (right) connectors Hard Shell-unlike molded connectors use replaceable terminal contacts. Replacement usually involves the use of a special terminal removal tool that depresses the locking tangs (barbs) on the connector terminal and allows the connector to be removed from the rear of the shell. The connector shell should be replaced if it shows any evidence of burning, melting, cracks, or breaks.
Page 350 Jumper wires are simple, yet extremely valuable, pieces of test equipment. They are basically test wires which are used to bypass sections of a circuit. Although jumper wires can be purchased, they are usually fabricated from lengths of standard automotive wire and whatever type of connector (alligator clip, spade connector or pin connector) that is required for the particular application being tested.
Page 351 The test light is used to check circuits and components while electrical current is flowing through them. It is used for voltage and ground tests. To use a 12 volt test light, connect the ground clip to a good ground and probe wherever necessary with the pick. The test light will illuminate when voltage is detected.
Page 352 the positive (+) side of the circuit (to the power source or the nearest power source). Note that the negative voltmeter lead will always be black and that the positive voltmeter will always be some color other than black (usually red). Ohmmeter-the ohmmeter is designed to read resistance (measured in ohms) in a circuit or component.
Page 353 Basic Troubleshooting When diagnosing a specific problem, organized troubleshooting is a must. The complexity of a modern automotive vehicle demands that you approach any problem in a logical, organized manner. There are certain troubleshooting techniques, however, which are standard: Establish when the problem occurs. Does the problem appear only under certain conditions? Were there any noises, odors or other unusual symptoms? Isolate the problem area.
Page 354 Testing Open Circuits Open circuit measurement This test already assumes the existence of an open in the circuit and it is used to help locate the open portion. 1. Isolate the circuit from power and ground. 2. Connect the self-powered test light or ohmmeter ground clip to the ground side of the circuit and probe sections of the circuit sequentially.
Page 355 2. Connect the self-powered test light or ohmmeter ground clip to a good ground and probe any easy-to-reach point in the circuit. 3. If the light comes on or there is continuity, there is a short somewhere in the circuit. 4.
Page 356 When current flows through a load, the voltage beyond the load drops. This voltage drop is due to the resistance created by the load and also by small resistances created by corrosion at the connectors and damaged insulation on the wires. The maximum allowable voltage drop under load is critical, especially if there is more than one load in the circuit, since all voltage drops are cumulative.
Page 357 Spark plug wire resistance CAUTION Never use an ohmmeter with power applied to the circuit. The ohmmeter is designed to operate on its own power supply. The normal 12 volt electrical system voltage could damage the meter! 1. Isolate the circuit from the vehicle's power source. 2.
Page 358 Battery Cables WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Disconnecting The Cables Before disconnecting the cable(s), first turn the ignition to the OFF position. This will prevent a draw on the battery which could cause arcing (electricity trying to ground itself to the body of a vehicle, just like a spark plug jumping the gap) and, of course, damaging some components such as the alternator diodes.
Page 359: Circuit Protection
ohmmeter range. A tester with a higher output could cause accidental deployment and possible injury. Do not put objects on the front passenger's airbag. The original radio has a coded theft protection circuit. Be sure to get the customer's radio and navigation system codes and write down the frequencies for the radio's preset stations before disconnecting the battery negative cable.
Page 360 WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Underhood Fuse Block 4.2L Engine Except Saab Underhood Fuse Block (2002 - 2005 Early Production)
Page 361 5.3L Engine Except Saab Underhood Fuse Block (2003 - 2005 Early Production)
Page 362: Entertainment Systems
Entertainment Systems WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Radio Removal & Installation To Remove: 1. For GMC vehicles, remove the lower closeout/insulator panel from the instrument panel (I/P). 2.
Page 363 8. Remove the radio from the instrument panel (I/P). To Install: 1. Place the radio in the instrument panel (I/P). 2. Connect the radio connectors. 3. Connect the radio antenna cable to the radio. 4. Install the radio into the instrument panel (I/P). 5.
Page 364: Cruise Control
Cruise Control WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Cruise Control Switch NOTE: The cruise control switch is integral to the turn signal/multifunction switch. Instruments & Switches Brake Light Switch Removal &...
Page 365 Headlamp Switch Removal & Installation To Remove: 1. Remove the access cover from the left of the instrument panel (I/P). Headlamp switch removal and installation 2. Release the headlamp switch retaining tabs behind the instrument panel (I/P). 3. Pull the headlamp switch out through the access hole. 4.
Page 366 Instrument Panel Cluster Removal & Installation To Remove: 1. Remove the left closeout insulator panel from the instrument panel (I/P). 2. Remove the knee bolster trim panel from the instrument panel (I/P). 3. Remove the instrument panel cluster (IPC) bezel from the instrument panel (I/P). Instrument panel cluster removal and installation 4.
Page 367 Front Fog Lamp Removal & Installation Chevrolet, GMC, and Isuzu To Remove: 1. Remove the fog lamp bulb and socket fro the fog lamp. Cornering and fog lamps (GMC and Chevrolet) 2. Detach the fog lamp from the fascia...
Page 368 To Install: 1. Attach the fog lamp to the fascia. Torque the nuts to 88 in-lb (10 Nm). 2. Install the fog lamp bulb and socket into the fog lamp. 3. Aim the fog lamp. Oldsmobile and Buick To Remove: 1.
Page 369 To Install: 1. Place the fog lamp onto the fog lamp bracket. 2. Install the fog lamp retaining pins into the fog lamp bracket. 3. Install the fog lamp aim adjustment screws. 4. Install the fog lamp bulb and socket into the fog lamp housing. 5.
Page 370 4. Install the headlamp assembly into the headlamp panel. Headlamp Assembly Chevrolet To Remove: Headlamp Assembly (Chevrolet) 1. Remove the grille from the front of the vehicle. 2. Release the headlamp assembly retaining tabs. 3. If equipped, disconnect the headlamp leveling motor connector.
Page 371 Aiming When adjusted properly, the lights should not glare in oncoming traffic's windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. CAUTION When headlights are replaced or any time front-end work is performed on the vehicle, the headlights should be aimed using the proper equipment.
Page 372 High-beam headlight pattern alignment 6. Perform the necessary repairs. 7. Turn the headlights ON. 8. Adjust the beams to match the marks on the wall.
Page 373 Cargo Lamp Removal & Installation To Remove: 1. Insert a flat bladed tool into the slot at the bottom of the cargo lamp and push up on the lamp. Cargo lamp removal and installation 2. Pull the bottom of the cargo lamp out from the body trim panel. 3.
Page 374 Dome Lamp Removal & Installation To Remove: 1. Remove the lens from the dome lamp. 2. Release the retaining tabs by moving the lamp forward. Dome lamp removal and installation 3. Remove the dome lamp from the headliner. 4. Disconnect the dome lamp connector. To Install: 1.
Page 375 High Mount Stop Lamp Removal & Installation To Remove: CAUTION Raising the liftgate with the liftgate window open can damage the high mount stop lamp, liftgate hinges, and the liftgate window. 1. Raise the liftgate. 2. Lower the rear of the headliner by removing the rear headliner pins. 3.
Page 376 Clearance Lamp Removal & Installation To Remove: 1. Turn the headlamp switch to the off position. Clearance lamp removal and installation 2. Remove the push pin from the clearance lamp. 3. Use a flat bladed tool to pry up the rear of the clearance lamp lens. 4.
Page 377 Rear License Lamp Removal & Installation To Remove: Rear license lamp 1. Detach the license lamp lens from the liftgate. 2. Remove the license lamp bulb from the socket. To Install: 1. Install the license lamp bulb into the socket. 2.
Page 378 Tail Lamp Assembly Removal & Installation To Remove: Tail lamp assembly removal and installation 1. Remove the tail lamp assembly retaining screws from the body. 2. Release the locking pins by pulling the assembly directly rearward. 3. Disconnect the tail lamp assembly connector. 4.
Page 379 6. WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Windshield Wiper Arm Removal & Installation To Remove: 1. Remove the wiper arm nut cover from the nut. Wiper arm removal and installation 2.
Page 380 Windshield Wiper Blade Removal & Installation To Remove: CAUTION Do not let the windshield wiper arm snap back against the windshield. 1. Pull the wiper arm into the upright position. Wiper blade (A), Wiper arm (B), Wiper blade clip locking tab (C) 2.
Page 381 Rear Window Wiper Arm Removal & Installation Except GMC Envoy XUV To Remove: Wiper arm removal and installation (Except GMC Envoy XUV) 1. With the wiper arm in the mid-wipe position, disconnect the washer hose from the wiper arm. 2. Remove the cover from the wiper arm. 3.
Page 382 GMC Envoy XUV To Remove: Wiper arm removal and installation (GMC Envoy XUV) 1. Remove the cover from the wiper arm. 2. Detach the wiper arm from the pivot shaft. 3. Disconnect the washer hose from the wiper arm. 4. Use a soft wire brush to clean the pivot shaft knurls. 5.
Page 383 11. Make sure the endgate window is operating properly. Rear Window Wiper Blade Removal & Installation Chevrolet, GMC (Except Envoy XUV), Oldsmobile, Buick, and Isuzu To Remove: CAUTION Do not let the windshield wiper arm snap back against the window.
Page 384 To Install: 1. Insert the wiper blade into the wiper arm opening. 2. Install the wiper blade onto the inside radius of the wiper arm. 3. Pull up on the wiper blade and engage the wiper blade clip locking tab. 4.
Page 385 Windshield Wiper Motor Removal & Installation To Remove: 1. Remove the windshield wiper arms from the pivot shafts. 2. Remove the air inlet grill from the vehicle. Windshield wiper transmission removal and installation 3. Remove the wiper transmission assembly retaining bolts from the vehicle. 4.
Page 386 Rear Window Wiper Motor Removal & Installation Except GMC Envoy XUV To Remove: 1. Remove the wiper arm from the pivot shaft. Rear window wiper motor removal and installation (Except GMC Envoy XUV) 2. Remove the nut and spacer form the pivot shaft. 3.
Page 387 GMC Envoy XUV To Remove: 1. Remove the wiper arm and spacer from the pivot shaft. 2. Remove the interior trim panel from the endgate. 3. Remove the window from the endgate. 4. Disconnect the rear wiper motor connector. Rear window wiper motor removal and installation (GMC Envoy XUV) 5.
Page 388 Windshield Wiper Switch NOTE: The windshield wiper switch is integral to the turn signal/multifunction switch. Rear Window Wiper/Washer Switch Removal & Installation Except Saab To Remove: 1. Remove the trim plate from the instrument panel (I/P). Rear window wiper/washer switch 2.
Page 389 Windshield Washer Pump Removal & Installation To Remove: 1. Remove the washer solvent container from the vehicle. Washer pump 2. Disconnect the washer hose from the windshield washer pump. 3. Pull the windshield washer pump from the retainer. 4. Remove and discard the grommet from the windshield washer pump. To Install: 1.
Page 390 Rear Window Washer Pump Removal & Installation To Remove: 1. Remove the washer solvent container from the vehicle. Washer pumps 2. Disconnect the washer hose from the rear window washer pump. 3. Pull the rear window washer pump from the retainer. 4.
Page 391 Doors WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Door Lock Actuator Removal & Installation To Remove: Remove the trim panel, water deflector, and door latch assembly from the door. Remove the door lock actuator retaining screws from the lock.
Page 392 To Install: 1. Install the rubber bumper into the latch. 2. Engage the rubber bumper by rotating the actuator toward the latch. 3. Install the door lock actuator onto the top of the latch, make sure that the first gear on the actuator is aligned to the first gear on the latch.
Page 393 To Install: 1. Install the rubber bumper into the latch. 2. Engage the rubber bumper by rotating the actuator toward the latch. 3. Install the liftgate lock actuator onto the top of the latch, make sure that the first gear on the actuator is aligned to the first gear on the latch. 4.
Page 394 5. Loosen the window regulator bolts in the keyhole slots, but do not remove the bolts. 6. Remove the remaining window regulator retaining bolts from the front door. 7. Lift the window regulator and push the bolts through the keyhole slots. 8.
Page 395 Rear window regulator removal and installation 5. Detach the window regulator from the rear door. 6. Detach the window regulator motor from the window regulator. To Install: 1. Attach the window regulator motor to the window regulator. Torque the bolts to 9 in-lb (5 Nm).
Page 396 Rear window regulator removal and installation 6. Detach the regulator cable from the rear door. 7. Loosen the window regulator bolt in the keyhole slot, but do not remove the bolts. 8. Remove the remaining window regulator retaining bolts from the rear door. 9.
Page 397 7. Torque the lower window regulator retaining bolt to 89 in-lb 10 (Nm). 8. Attach the regulator cable to the rear door. 9. Connect the window regulator connector. 10. Lower the window into the carrier and loosely tighten the bolts. 11.
Page 398: Power Seats
Power Seats WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Power Seat Adjuster Mechanism Removal & Installation To Remove: 1. Remove the seat from the vehicle. 2. Remove the trim panel from the seat. 3.
Page 399 7. Detach the power seat adjuster from the seat pan. 8. Remove the seat back from the seat. 9. If replacing the adjuster mechanism, remove the seat position sensor from the mechanism. To Install: 1. If replacing the adjuster mechanism, install the seat position sensor into the mechanism.
Page 400 Front Seat Lumbar Assembly Removal & Installation To Remove: 1. Remove the front seat from the vehicle. 2. Remove the cover and pad from the seat back. 3. Remove the panel from the seat back. 4. Disconnect the lumbar motor connector. 5.
Page 401: Drive Train
DRIVE TRAIN Precautions Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: Always wear safety goggles or some type of eye/face protection when working with, around or under a vehicle.
Page 402 Cleanliness and Care, Shop Practice It should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. When any internal engine parts are serviced, care and cleanliness is important. When components are removed for service, they should be marked, organized or retained in a specific order for reassembly.
Page 403: Automatic Transaxle
Automatic Transaxle WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Understanding the Automatic Transmission The automatic transmission allows engine torque and power to be transmitted to the rear wheels within a narrow range of engine operating speeds. It will allow the engine to turn fast enough to produce plenty of power and torque at very low speeds, while keeping it at a sensible rpm at high vehicle speeds (and it does this job without driver assistance).
Page 404 Torque converter The torque converter housing is rotated by the engine's crankshaft, and turns the impeller. The impeller then spins the turbine, which gives motion to the turbine shaft, driving the gears. The impeller is turning faster than the turbine. It picks up fluid at the center of the converter and, through centrifugal force, slings it outward.
Page 405 impeller to turn much faster than the turbine. This difference in speed may be compared to the difference in speed between the smaller and larger gears in any gear train. The result is that engine power output is higher, and engine torque is multiplied. As the speed of the turbine increases, the fluid spins faster and faster in the direction of engine rotation.
Page 406 Planetary gears function very similarly to conventional transmission gears. However, their construction is different in that three elements make up one gear system, and, in that all three elements are different from one another. The three elements are: an outer gear that is shaped like a hoop, with teeth cut into the inner surface;...
Page 407 Most automatics use the planetary gears to provide various reductions ratios. Bands and clutches are used to hold various portions of the gear sets to the transmission case or to the shaft on which they are mounted. Shifting is accomplished, then, by changing the portion of each planetary gear set which is held to the transmission case or to the shaft.
Page 408 Most automatic transmissions are electronically controlled; electrical solenoids are used to control the hydraulic fluid. The shift solenoids are regulated by an electronic control module. Shift timing is regulated through sensor feedback information provided to the electronic controller. On older transmissions there are two pressures that control the shift valves. One is the governor pressure which is affected by vehicle speed.
Page 409 Transmission Removal & Installation 4.2L Engine 2002, 2003 To Remove: 1. Disconnect the negative battery cable. 2. Detach the filler tube from the right side of the engine. 3. Lift the vehicle. 4. Drain the fluid from the transmission. 5. Remove the rear propeller shaft from the vehicle. 6.
Page 410 20. Remove the torque converter access plug from the transmission. 21. Mark the orientation of the flywheel and torque converter. 22. Remove the flywheel bolts from the torque converter. 23. Disconnect the transmission oil cooler lines from the transmission. 24. Plug the transmission oil cooler lines holes in the transmission. 25.
Page 411 To Install: 1. Lift the transmission. 2. Remove the J 21366 converter holding strap from the bell housing. 3. Install the transmission onto the engine by pushing the transmission forward. Make sure the transmission is aligned with the locator pins and the torque converter is aligned with the mark on the flywheel.
Page 412 7. Remove the transmission support from the frame. 8. Detach the transmission mount from the transmission. 9. Remove the front exhaust pipe from the vehicle. 10. Lower the transmission enough to gain access to the top of the transmission. 11. If equipped, remove the transfer case from the vehicle. 12.
Page 413 21. Plug the transmission oil cooler lines holes in the transmission. 22. Install a safety chain around the transmission. 23. Detach the filler tube from the transmission. Transmission removal and installation 24. Remove the transmission nuts, studs, and bolts from the engine. 25.
Page 414 To Install: 1. Lift the transmission. 2. Remove the J 21366 converter holding strap from the bell housing. 3. Install the transmission onto the engine by pushing the transmission forward. Make sure the transmission is aligned with the locator pins and the torque converter is aligned with the mark on the flywheel.
Page 415 Transmission Fluid Fluid Level Checking Pre-Check Procedure 1. Park the vehicle on a level surface and start the engine. 2. Apply the parking brake and make sure the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range.
Page 416 Hot Check Procedure CAUTION Use this procedure to check the transmission fluid level when the fluid temperature is between 180-200°F (82-93°C). The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1.
Page 417 Park/Neutral Position Switch Removal & Installation To Remove: 1. Apply the parking brake. 2. Shift the transmission to the neutral position. 3. Lift the vehicle. 4. Detach the transmission control lever from the manual shaft. 5. Disconnect the park/neutral position switch connector. Park/neutral position switch removal and installation 6.
Page 418 J 41364-A removal and installation 3. NOTE: It will not be necessary to use a J 41364-A park/neutral switch aligner if installing a new switch. A new switch will come with a positive assurance bracket. 4. Install a J 41364-A park/neutral switch aligner onto the switch. 5.
Page 419 Adjustment NOTE: Only perform this procedure if the park/neutral position switch is not being removed or replaced. If the park/neutral position switch is being removed or replaced, use the removal and installation procedure. 1. Apply the parking brake. 2. Make sure the engine will only start with the transmission in the park or neutral positions.
Page 420 3. Remove the range selector lever cable from the transmission range selector lever ball stud. 4. Remove the range selector lever cable retainer from the range selector bracket. 5. Remove the range selector lever cable from the range selector bracket. 6.
Page 421 To Install: 1. Insert the range selector lever cable through the hole in the floor panel. 2. Install the range selector lever cable grommet into the floor panel by pushing down on the grommet from inside the vehicle. 3. Attach the range selector lever cable to the floor shift control assembly. 4.
Page 422 Adjustment 1. Make sure the range selector lever cable is not restricted. 2. Shift the transmission to the park position. 3. Lift the vehicle. Range selector lever (A), Range selector lever cable bracket (B), Range selector lever cable (C), Range selector lever cable retainer (D), Range selector lever cable end (E) 4.
Page 423 Range selector lever cable 6. Release the range selector lever cable end secondary locking tab. 7. Slide the range selector lever cable end secondary lock off of the primary lock. 8. Disengage the range selector lever cable end primary lock by squeezing the locking tabs together.
Page 424 Transmission Fluid Pan & Filter Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the catalytic converter from the vehicle. 3. Place a drain pan under the transmission fluid pan. 4. If equipped, remove the transmission fluid pan drain plug from the transmission fluid pan.
Page 425 Driveline & U-Joints WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Front Propeller Shaft Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the steering gear crossmember from the frame. Front axle pinion yoke 3.
Page 426 5. Disconnect the front propeller shaft from the front axle pinion yoke. 6. To prevent the loss of bearing rollers, wrap the bearing caps with tape. Front propeller shaft removal and installation 7. Remove the front propeller shaft from the transfer case output shaft. To Install: 1.
Page 427 Rear Propeller Shaft Removal & Installation To Remove: 1. Lift the vehicle. 2. Mark the orientation of the rear propeller shaft to the rear axle pinion yoke. 3. Mark the orientation of the rear propeller shaft to the transmission or transfer case. Rear axle pinion yoke retainer removal and installation 4.
Page 428 To Install: 1. Apply GM P/N 12377985 grease to the slip yoke. 2. Align the rear propeller shaft to the marks on the transmission or transaxle. 3. Install the rear propeller shaft into the transmission or transaxle. 4. Align the rear propeller shaft to the marks on the rear axle pinion yoke. 5.
Page 429 Universal Joint Removal & Installation External Snap Ring To Remove: 1. Lay the propeller shaft on table level with the press table. 2. Mark the transmission and rear axle ends of the propeller shaft. 3. Remove the snap rings by using a pair of pliers to squeeze the ends together. 4.
Page 430 Nylon Injected Ring To Remove: 1. Lay the propeller shaft on table level with the press table. 2. Mark the transmission and rear axle ends of the propeller shaft. 3. Set the lower ear of the yoke on a 1-1/8 in (30 mm) socket. 4.
Page 431 Universal Joint Removal & Installation External Snap Ring To Remove: 1. Lay the propeller shaft on table level with the press table. 2. Mark the transmission and rear axle ends of the propeller shaft. 3. Remove the snap rings by using a pair of pliers to squeeze the ends together. 4.
Page 432 2. Mark the transmission and rear axle ends of the propeller shaft. 3. Set the lower ear of the yoke on a 1-1/8 in (30 mm) socket. 4. Use a J9522-3 universal joint bearing separator on the open horizontal bearing cups to press the lower bearing cup out of the yoke ear.
Page 433 Differential Carrier Assembly Removal & Installation 4.2L Engine To Remove: 1. Remove the front wheels from the vehicle. 2. Remove the engine protection shield from under the frame. 3. Drain the fluid from the differential carrier. 4. Remove the front propeller shaft from the differential carrier. 5.
Page 434 8. Remove the nut and bolt from the upper ball pinches. Shock module retaining nuts removal and installation 9. Remove the retaining nuts from the upper shock modules. 10. Remove the front stabilizer bar links and shock modules from the frame. 11.
Page 435 Power steering gear assembly removal and installation 15. Remove the power steering gear assembly from the vehicle. 16. Remove the inner shaft from the differential carrier. 17. Detach the differential carrier from the oil pan and secure it to the frame. 18.
Page 436 13. Install the front stabilizer bar links to the frame. 14. Attach the brake hose retainers to the frame. Torque the bolts to 18 ft-lb (25 Nm). 15. Attach the antilock brake system (ABS) harnesses to the wheel wells. 16. Install the front propeller shaft into the differential carrier. 17.
Page 437 Upper ball pinch nut and bolt removal and installation 10. Remove the nut and bolt from the upper ball pinches. 11. Remove the steering knuckles from the upper control arms.
Page 438 Shock module retaining nuts removal and installation 12. Remove the retaining nuts from the upper shock modules. 13. Lower the jack stands supporting the lower control arms. 14. Remove the front wheel drive shafts from the differential carrier using a brass drift. 15.
Page 439 To Install: 1. Secure the differential carrier to the frame. 2. Install the oil pan onto the engine. 3. Attach the differential carrier to the oil pan. Torque the bolts to 63 ft-lb (85 Nm). 4. Install the inner shaft into the differential carrier. 5.
Page 440 Axle Housing Bushing Removal & Installation To Remove: 1. Raise and safely support the vehicle. 2. Remove the control arm from the axle housing. 3. Use a commercially available bushing remover/installer to remove the bushing from the axle housing. To Install: 1.
Page 441 4. Remove and discard the outboard intermediate shaft bearing oil seal from the intermediate shaft bearing. Intermediate shaft bearing (Automatic 4WD) Intermediate shaft bearing (Selectable 4WD)
Page 442 6. For vehicles with selectable 4WD, disconnect the actuator connector. 7. Detach the wire harness from the intermediate shaft bearing. 8. Detach the intermediate shaft bearing from the oil pan. Actuator removal and installation 9. For vehicles with selectable 4WD, detach the actuator from the intermediate shaft bearing.
Page 443 J 29369-2 and J 2619-01 Installation 11. Install a J 29369-2 bushing and bearing remover and a J 269-01 slide hammer with adapter into the inboard intermediate shaft bearing oil seal. 12. Remove and discard the inboard intermediate shaft bearing oil seal from the intermediate shaft bearing.
Page 444 To Install: J 45225 and J 8029 installation 1. Install a new inboard intermediate shaft bearing oil seal into the intermediate shaft bearing using a J 45225 axle seal installer and a J 8092 universal driver handle. 2. For vehicles with selectable 4WD, attach the actuator to the intermediate shaft bearing.
Page 445 3. Attach the intermediate shaft bearing onto the oil pan. Torque the bolts to 35 ft-lb (48 Nm). 4. Attach the wire harness to the intermediate shaft bearing. 5. For vehicles with selectable 4WD, connect the actuator connector. J 45359 and J 8092 installation 6.
Page 446 Drive Pinion Seal Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the engine protection shield from under the frame. 3. Drain the fluid from the differential carrier. 4. Remove the front propeller shaft from the vehicle. 5. Remove the steering gear crossmember from the frame. Drive pinion torque measurement 6.
Page 447 10. Install a J 8614-2 and a J 8614-3 into the J 8614-01 flange and pulley holding tool. 11. Hold the J 8614-01 flange and pulley holding tool while turning the J 8614-3 clockwise to remove the pinion yoke. NOTE: Make sure not to distort or scratch the aluminum case while removing the seal from the bore.
Page 448 2. Use a J 33782 and a hammer to install the pinion seal into the drive pinion. 3. Apply GM P/N 12346004 or equivalent to the drive pinion yoke splines. 4. Align the pinion yoke to the marks on the drive pinion shaft. 5.
Page 449: Rear Axle
Rear Axle WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Axle Housing Assembly Removal & Installation To Remove: 1. Lift the vehicle. 2. Drain the lubricant from the rear axle housing. 3.
Page 450 Axle Housing Bushing Removal & Installation To Remove: 1. Raise and safely support the vehicle. 2. Remove the control arm from the axle housing. 3. Use a commercially available bushing remover/installer to remove the bushing from the axle housing. To Install: 1.
Page 451 Axle shaft removal and installation 11. Remove the axle shaft from the rear axle housing. J 45859 and J 2619-01 Installation...
Page 452 12. If necessary, use a J 45859 axle remover and a J 2619-01 slide hammer to remove the axle shaft from the rear axle housing. To Install: 1. Install the axle shaft into the rear axle housing. 2. Engage the axle shaft splines with the differential side gear. 3.
Page 453 J 45857 and J 2619-01 Installation 5. Use a J 45857 bearing remover and a J 2619-01 slide hammer to remove the axle shaft bearing and seal. To Install: J 23690 and J 8092 Installation 1. Use a J 23690 bearing installer and a J 8092 universal driver handle to install the axle shaft bearing.
Page 454 J 21128 Installation 2. Use a J 21128 axle pinion oil seal installer to install the axle shaft seal. 3. Install the axle shaft into the vehicle. 4. Install the cover and gasket onto the rear axle housing. 5. Install the wheel onto the vehicle. 6.
Page 455 Drive Pinion Seal Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the rear wheels. 3. Remove the rear brake calipers and rotors from the rear hubs. 4. Remove the rear propeller shaft from the vehicle. Drive pinion torque measurement 5.
Page 456 7. Install a J 8614-01 flange and pulley holding tool onto the drive pinion. 8. Remove the pinion nut from the pinion while holding the J 8614-01 flange and pulley holding tool. 9. Install a J 8614-2 and a J 8614-3 into the J 8614-01 flange and pulley holding tool. 10.
Page 457: Transfer Case
Transfer Case Front Output Shaft Seal Removal & Installation To Remove: 1. Lift the vehicle. 2. If equipped, remove the fuel tank shield from the fuel tank. 3. If equipped, remove the transfer case shield from the transfer case. 4. Remove the front propeller shaft from the vehicle. 5.
Page 458 To Install: Front output shaft seal installation 1. Install a J 45236-2 front output shaft seal installer onto the front output shaft. 2. Install the front output shaft seal over the J 45236-2 front output shaft seal installer. 3. Install the front output shaft seal onto the front output shaft using a J 45236-1 front output shaft seal installer.
Page 459 Rear Output Shaft Seal Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the rear propeller shaft from the vehicle. Rear output shaft seal removal 3. Remove the rear output shaft seal from the rear output shaft by prying it away.
Page 460 To Install: Rear output shaft seal installation 1. Install the rear output shaft seal onto the rear output shaft using a J 37668-A output shaft seal installer. 2. Install the rear propeller shaft into the vehicle. 3. Check the fluid level in the transfer case. 4.
Page 461 Transfer Case Assembly Removal & Installation NP4 & NP8 Transfer Cases To Remove: 1. Lift the vehicle. 2. If equipped, remove the fuel tank shield from the fuel tank. 3. If equipped, remove the transfer case shield from the transfer case. 4.
Page 462 To Install: NOTE: Replace the transfer case gasket if it is damaged. 1. Install the gasket onto the transfer case. 2. Lift the transfer case. 3. Install the transfer case mounting nuts into the transfer case adapter. Torque the nuts to 35 ft-lb (47 Nm). 4.
Page 463 7. Remove the transfer case mounting nuts from the transfer case adapter. 8. Lower the transfer case. 9. Detach the electrical harness from the transfer case. 10. Remove the gasket from the transfer case. To Install: NOTE: Replace the transfer case gasket if it is damaged. 1.
Page 464 Half Shafts & CV-Joints WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Half Shafts Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the front wheels from the vehicle. 3.
Page 465 Upper ball pinch nut and bolt removal and installation 10. Remove the nut and bolt from the upper ball pinch joints. 11. Remove the shock modules from the shock towers. 12. Remove the steering knuckles from the upper control arms. 13.
Page 466 To Install: 1. Install the left half shaft into the differential carrier. 2. Install the right half shaft into the clutch fork housing. 3. Remove the wiring supporting the shock modules and steering knuckles to the frame. 4. Install the half shafts into the steering knuckles. 5.
Page 467 Removal & Installation Double Offset Joint To Remove: NOTE: The Double Offset Joint (D.O.J.) is bigger than other joints and, in these applications, is normally used as an inboard joint. 1. Remove the halfshaft from the vehicle. 2. Side cutter pliers can be used to cut the metal retaining bands. Remove the boot from the joint outer race.
Page 468 4. If the boot is be reused, wrap vinyl tape around the spline part of the shaft so the boot(s) will not be damaged when removed. Remove the dynamic damper, if used, and the boots from the shaft. To Install: 1.
Page 469 Removing the outer band from the CV-boot Removing the inner band from the CV-boot...
Page 470 Removing the CV-boot from the joint housing Clean the CV-joint housing prior to removing boot...
Page 471 Removing the CV-joint housing assembly Removing the CV-joint...
Page 472 Inspecting the CV-joint housing Removing the CV-joint outer snap ring...
Page 473 Checking the CV-joint snap ring for wear CV-joint snap ring (typical)
Page 474 Removing the CV-joint assembly Removing the CV-joint inner snap ring...
Page 475 Installing the CV-joint assembly (typical)
Page 476 STEERING AND SUSPENSION Precautions Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: Always wear safety goggles or some type of eye/face protection when working with, around or under a vehicle.
Page 477 WARNING To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches.
Page 478 Vehicles equipped with safety canopy modules are also equipped with seat side air bag modules. Safety canopy modules deploy from the headliner, protecting the first and second row outboard occupants or first, second and third row outboard occupants during a side impact or if a rollover condition is detected.
Page 479 Ignition Lock Cylinder Removal & Installation Except Saab To Remove: 1. Disable the SIR system by disconnecting the negative battery cable. 2. Remove the left insulator panel and knee bolster from under the instrument panel (I/P). 3. Remove the trim covers from the steering column. 4.
Page 480 Ignition Switch Removal & Installation Except Saab To Remove: 1. Disable the SIR system by disconnecting the negative battery cable. 2. Remove the left insulator panel and knee bolster from under the instrument panel (I/P). 3. Remove the trim covers from the steering column. 4.
Page 481 Use the special tool to release the tabs on the ignition switch 8. Release the ignition switch tabs by inserting a J 42759 ignition switch connector release tool into the ignition lock cylinder housing. Ignition switch removal/installation...
Page 482 9. Remove the ignition switch from the ignition lock cylinder housing. 10. Disconnect the ignition switch connector. To Install: Turn the gear to the position shown 1. Turn the ignition switch gear until it is in the position shown above. 2.
Page 483 Turn Signal/Multifunction Switch Removal & Installation To Remove: 1. Disable the SIR system by disconnecting the negative battery cable. 2. Remove the trim covers from the steering column. 3. Tilt the steering column to the center position. 4. Disconnect the turn signal/multifunction switch connectors. 5.
Page 484 Power Steering Pump Removal & Installation 4.2L Engine To Remove: 1. Remove the air cleaner assembly from the engine compartment. 2. Remove the drive belt from the pulleys. 3. Place a drain pan under the vehicle. Power steering pump hoses removal and installation (4.2L) 4.
Page 485 Power steering pump removal and installation (4.2L) 6. Detach the power steering pump from the engine. 7. Remove the power steering pump pulley from the power steering pump. To Install: 1. Install the power steering pump pulley onto the power steering pump. 2.
Page 486 5.3L & 6.0L Engines To Remove: 1. Remove the drive belt from the pulleys. 2. For 2005-2007 vehicles, remove the engine control module (ECM) from the mounting bracket and set aside. 3. For 2003-2004 vehicles, remove the powertrain control module (PCM) from the mounting bracket and set aside.
Page 487 Power steering pump removal and installation (5.3L/6.0L) 6. Detach the power steering pump from the engine. 7. Remove the power steering pump pulley from the power steering pump. To Install: 1. Install the power steering pump pulley onto the power steering pump. 2.
Page 488 Power Steering Hose Assembly Removal & Installation 4.2L Engine To Remove: 1. Lift the vehicle. 2. Remove the engine protection shield from under the frame. 3. Place a drain pan under the vehicle. Power steering gear hoses removal and installation (4.2L) 4.
Page 489 Power steering cooler hoses removal and installation 5. Disconnect the power steering return and cooler hoses from the power steering cooler. Power steering pump hoses removal and installation (4.2L)
Page 490 6. Disconnect the power steering pressure and cooler hoses from the power steering pump. 7. Lower the vehicle. 8. Detach the power steering hose assembly from the front crossmember. 9. Remove the battery and battery tray from the vehicle. 10. Remove the underhood fuse block cover. 11.
Page 491 Power steering gear oil seal removal 21. Use the removal end of a J 44586 power steering gear oil seal remover/installer and a flat head screwdriver to remove the power steering gear oil seal from the power steering gear. Discard the seal.
Page 492 To Install: Power steering gear oil seal installation 1. Use the installation end of a J 44586 power steering gear oil seal remover/installer to install a new power steering gear oil seal into the power steering gear. 2. Lower the vehicle. 3.
Page 493 11. Attach the negative battery cable to the fender and fuse block. 12. Install the underhood fuse block cover. 13. Install the battery and battery tray into the vehicle. 14. Attach the power steering hose assembly to the front crossmember. Torque the bolt to 89 in-lb (10 Nm).
Page 494 Power steering cooler hoses removal and installation 4. Disconnect the power steering return and cooler hoses from the power steering cooler. 5. Lower the vehicle. Power steering pump hoses removal and installation (5.3L/6.0L)
Page 495 6. Disconnect the power steering pressure and pump return hoses from the power steering pump. 7. For 2003 through 2004 vehicles, remove the powertrain control module (PCM) from the mounting bracket and set it aside. 8. For 2005 through 2007 vehicles, remove the engine control module (ECM) from the mounting bracket and set it aside.
Page 496 Power steering gear oil seal removal 13. Use the removal end of a J 44586 power steering gear oil seal remover/installer and a flat head screwdriver to remove the power steering gear oil seal from the power steering gear. Discard the seal. To Install: Power steering gear oil seal installation...
Page 497 1. Use the installation end of a J 44586 power steering gear oil seal remover/installer to install a new power steering gear oil seal into the power steering gear. 2. Lower the vehicle. 3. Place the power steering hose assembly into the engine compartment. 4.
Page 498 Steering Gear Removal & Installation To Remove: 1. Lift the vehicle. 2. Place a drain pan under the vehicle. 3. Remove the front wheels from the vehicle. Outer tie rod retaining nut removal and installation 4. Remove the retaining nuts from the outer tie rod ends.
Page 499 J 24319-B steering linkage and tie rod puller 5. Use a J 24319-B steering linkage and tie rod puller to detach the outer tie rod ends from the steering knuckles. 6. Remove the steering gear crossmember from under the vehicle. 7.
Page 500 Power steering gear assembly removal and installation 11. Remove the steering gear from the vehicle. 12. Remove the outer tie rods from the inner tie rods. To Install: 1. Install the outer tie rods into the inner tie rods. 2. Install the steering gear into the vehicle. 3.
Page 501 Power Steering Fluid Filling & Bleeding NOTE: Always use new power steering fluid when filling. NOTE: Make sure that no hoses touch the frame. Hoses touching the frame may cause system noise. NOTE: Make sure that all hose connections are tight. Loose connection might not leak, but do allow air into the system.
Page 502 Steering Column Removal & Installation To Remove: 1. Turn the steering wheel to point the front wheels straight-ahead. 2. Disconnect the negative battery cable to disable the supplemental inflatable restraint (SIR) system. J 42640 installation 3. Insert a J 42640 steering column anti-rotation pin through the access hole in the lower steering column trim cover to lock the steering column in place.
Page 503 Steering column removal and installation 12. Remove the mounting nuts from the steering column. 13. Remove the steering column from the vehicle. To Install: 1. Place the steering column into the vehicle. 2. Install the mounting nuts into the steering column. Torque the nuts to 20 ft-lb (27 Nm).
Page 504 11. Install the knee bolster under the instrument panel. 12. Install the steering wheel onto the steering column. 13. Remove the J 42640 steering column anti-rotation pin from the access hole in the lower steering column trim cover to unlock the steering column. 14.
Page 505 To Install: 1. Install the steering wheel onto the steering column. 2. Install the steering wheel nut onto the steering wheel shaft. Torque the nut to 30 ft- lb (41 Nm). 3. Connect the steering wheel connector. 4. Install the horn plunger into the steering wheel. 5.
Page 506 Tie Rod End Removal & Installation Inner Tie Rod End To Remove: Inner tie rod assembly (Magnasteer)
Page 507 Left inner tie rod housing (A), Left shock dampener (B), Inner tie rod assembly (Quiet Valve) (C), Right shock dampener (D), Right rack (E), Right inner tie rod housing (F) 1. Remove the rack and pinion boot from the inner tie rod assembly. 2.
Page 508 To Install: 1. Move the right shock dampener onto the right rack. 2. If the rack is female, and the inner tie rod is male, coat the inner tie rod threads with LOCTITE ® 262 or equivalent sealant. 3. Attach the right inner tie rod to the right rack. 4.
Page 509 Outer Tie Rod End To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. Outer tie rod retaining nut removal and installation 3. Remove and discard the retaining nut from the outer tie rod.
Page 510 J 24319-B steering linkage and tie rod puller 4. Use a J 24319-B steering linkage and tie rod puller to detach the outer tie rod from the steering knuckle. 5. Remove the outer tie rod from the inner tie rod by loosening the jam nut. 6.
Page 511: Front Suspension
8. Front Suspension 9. WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Upper Control Arm Ball Joint Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3.
Page 512 4. Remove the retaining clip from the upper ball joint. 5. Remove the boot from the upper ball joint. Upper ball joint removal 6. Use a J 9519-E ball joint remover and installer to remove the upper ball joint from the steering knuckle.
Page 513 To Install: Upper ball joint installation 1. Use a J 9519-E ball joint remover and installer, J21474-01 control arm bushing set, and J 45117 ball joint installation spacer to install the upper ball joint onto the steering knuckle. 2. Install the retaining clip onto the upper ball joint. 3.
Page 514 Lower Control Arm Ball Joint Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3. Remove the steering knuckle from the vehicle. 4. Use a chisel to remove the flange from the lower ball joint. Lower ball joint removal 5.
Page 515 To Install: Lower ball joint installation 1. Use a J 9519-E ball joint remover and installer, J 41435 ball joint installer, and J 45105-2 receiver to install the lower ball joint onto the lower control arm. 2. Use a J 9519-E ball joint remover and installer and J 45105-1 ball joint flaring adapter to flare the lower ball joint flange.
Page 516 Upper Control Arm Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the front wheel from the vehicle. Upper ball pinch nut and bolt removal and installation 3. Remove and discard the nut and bolt from the upper control arm pinch. 4.
Page 517 Upper control arm removal and installation 8. Detach the upper control arm from the frame. To Install: 1. Attach the upper control arm to the frame. Torque the mounting bolts to 108 ft-lb (146 Nm). 2. If installing the left upper control arm, install the battery and battery tray into the engine compartment.
Page 518 Lower Control Arm Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. Outer tie rod retaining nut removal and installation 3. Remove and discard the retaining nut from the outer tie rod. 4. Use a J 36607 steering linkage and tie rod puller to disconnect the outer tie rod from the steering knuckle.
Page 519 Shock absorber module yoke nut removal and installation 6. Remove the mounting nut from the shock absorber module yoke. 7. Use a J 36607 steering linkage and tie rod puller to disconnect the shock absorber module yoke from the lower control arm. 8.
Page 520 9. Use a J 43631 ball joint remover to disconnect the lower ball joint from the steering knuckle. Lower control arm removal and installation 10. Remove the lower control arm mounting nuts from the lower control arm mounting bracket. NOTE: Make note of the direction of the mounting bolts for reassembly. 11.
Page 521 Hub & Bearing Removal & Installation To Remove: Drive axle nut removal and installation 1. For vehicles with 4wd, remove the nut from the drive axle. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. 4. Remove the brake rotor from the hub. 5.
Page 522 Hub and bearing removal and installation 7. Detach the hub and bearing from the steering knuckle. 8. Remove the splash shield from the steering knuckle. To Install: 1. Install the splash shield into the steering knuckle. 2. Attach the hub and bearing to the steering knuckle. Torque the bolts to 77 ft-lb (105 Nm).
Page 523 Steering Knuckle Removal & Installation To Remove: Drive axle nut removal and installation 1. For vehicles with 4WD, remove the nut from the drive axle. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. 4. Remove the hub and bearing from the steering knuckle.
Page 524 Outer tie rod retaining nut removal and installation 5. Remove and discard the retaining nut from the outer tie rod end. J 24319-B steering linkage and tie rod puller...
Page 525 6. Use a J 24319-B steering linkage and tie rod puller to detach the outer tie rod. 7. Detach the brake hose bracket from the steering knuckle. 8. Detach the wheel speed sensor from the steering knuckle. Upper ball pinch nut and bolt removal and installation 9.
Page 526 Lower ball joint removal 12. Use a J 43631 ball joint remover to disconnect the lower ball joint from the steering knuckle. 13. Remove the steering knuckle from the vehicle. To Install: 1. Install the steering knuckle onto the lower control arm. 2.
Page 527 Shock Absorber Module Removal & Installation To Remove: Shock module retaining nuts removal and installation 1. Remove the upper retaining nuts from the shock absorber module. 2. Lift the vehicle. 3. Remove the wheel from the vehicle.
Page 528 Shock absorber module yoke nut removal and installation 4. Loosen the mounting nut from the shock absorber module yoke. 5. Use a J 36607 ball joint separator to remove the yoke from the lower control arm. 6. Remove the J 36607 ball joint separator and retaining nut from the shock absorber module yoke.
Page 529 Shock Absorber Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3. Remove the shock absorber module from the vehicle. Shock absorber module yoke pinch bolt removal and installation 4. Remove the shock absorber module yoke pinch nut and bolt from the shock absorber.
Page 530 J 45400 8. Turn the J 45400 strut spring compressor compression screw to compress the shock absorber module spring. 9. Remove the upper retaining nut and washer from the shock absorber. 10. Remove the shock absorber from the shock absorber module. 11.
Page 531 To Install: 1. Install the coil spring and upper mounting plate into the J 45400 strut spring compressor. 2. Turn the J 45400 strut spring compressor compression screw to compress the shock absorber module spring. 3. Install the washer, dust boot, jounce bumper, and lower spring isolator onto the shock absorber.
Page 532 Stabilizer Shaft Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheels from the vehicle. 3. Remove the stabilizer shaft links from the stabilizer shaft. Stabilizer shaft insulator clamp removal and installation 4. Detach the stabilizer shaft insulator clamps from the stabilizer shaft. 5.
Page 533 9. For vehicles with a 4.2L engine, lift the engine off of the front suspension crossmember. 10. Remove the stabilizer shaft from the vehicle. To Install: 1. Install the stabilizer shaft into the vehicle. 2. For vehicles with a 4.2L engine, lower the. 3.
Page 534: Rear Suspension
Rear Suspension WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Coil Spring Removal & Installation To Remove: 1. Lift the vehicle. 2. Install a support for the rear axle. Shock absorber mounting bolt removal and installation 3.
Page 535 Coil spring removal and installation 5. Remove the rear coil spring from the vehicle. To Install: 1. Install the rear coil spring into the vehicle. 2. Lift the rear axle. 3. Install the lower mounting bolts into the shock absorber. 4.
Page 536 Upper Control Arm Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3. Remove the panel from the wheelhouse. 4. Lift the rear axle to drive height. 5. If equipped with air suspension, depressurize the air suspension system. 6.
Page 537 Upper control arm frame mounting bolt removal and installation 8. Detach the upper control arm the axle and frame. To Install: 1. Install the upper control arm into the vehicle. 2. Attach the upper control arm the axle and frame. Torque the bolts to 97 ft-lb (131 Nm).
Page 538 Lower Control Arm Removal & Installation To Remove: 1. Lift the vehicle. 2. Lift the rear axle to drive height. 3. If equipped with air suspension, depressurize the air suspension system. Lower control arm axle mounting bolt removal and installation Lower control arm frame mounting bolt removal and installation 5.
Page 539 To Install: 1. Attach the lower control arm to the axle and frame. Torque the bolts to 74 ft-lb (100 Nm). 2. Lower the rear axle. 3. Lower the vehicle. Shock Absorber Removal & Installation To Remove: 1. Lift the vehicle. 2.
Page 540 To Install: 1. Install the shock absorber into the vehicle. 2. Install the lower mounting bolt into the shock absorber. Torque the bolt to 63 ft-lb (85 Nm). 3. Install the upper mounting bolt into the shock absorber. Torque the bolt to 63 ft-lb (85 Nm).
Page 541 Stabilizer shaft insulator clamp mounting nut removal and installation 4. Remove the mounting nuts from the stabilizer shaft insulator clamps. 5. Remove the stabilizer shaft from the vehicle. 6. Remove the stabilizer shaft insulators from the stabilizer shaft. To Install: 1.
Page 542 Rear Axle Brace Removal & Installation To Remove: 1. Lift the vehicle. 2. Lift the rear axle to drive height. 3. If equipped with air suspension, depressurize the air suspension system. Rear axle brace tie rod mounting bolt removal and installation 4.
Page 543 Rear axle frame mounting nut removal and installation 5. Remove the rear axle brace mounting nut from the frame. 6. Remove the rear axle brace from the vehicle. To Install: 1. Install the rear axle brace into the vehicle. 2. Install the rear axle brace mounting nut onto the frame. Torque the nut to 70 ft-lb (95 Nm).
Page 544 Wheels & Tires WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Wheels Inspection Tires should be inspected to ensure that there are no lacerations, puncture marks, nails and other sharp objects compromising the integrity of the tread area and sidewall. When inspecting the tires, check for proper air pressure and adequate tread depth.
Page 545 Wheel Lug Studs Removal & Installation Front Disc Brakes W/Integral Hub & Rotor To Remove: 1. Raise and safely support the vehicle. 2. Remove the wheel and tire assembly. CAUTION Failure to support the brake caliper could result in brake hose failure. 3.
Page 546 Pressing the stud from the rotor 8. Drive the stud out using an arbor press. NOTE: If a press is not available, carefully drive the old stud out using a blunt drift. Ensure that the rotor is properly and evenly supported or damage may result. To Install: 1.
Page 547 Stud installation 2. Finish installing the stud with the press. NOTE: If a press is not available, use the following procedure: A. Start the lug stud through the bore in the hub. B. Place approximately four flat washers over the stud and thread the lug nut to the stud.
Page 548 Wheel lug nut tightening sequence H. Torque the lug nuts to specification. Lower the vehicle Front & Rear Disc Brakes W/Removable Rotor To Remove: 1. Raise and safely support the vehicle. 2. Remove the wheel and tire assembly. CAUTION Failure to support the brake caliper could result in brake hose failure. 3.
Page 549 Removing stud with C-clamp and socket 6. Use a large C-clamp and socket to press the stud from the hub/axle flange. To Install: 1. Clean the stud hole with a wire brush. 2. Start the lug stud through the bore in the hub/axle flange. Installing lug stud...
Page 550 3. Place approximately four flat washers over the stud and thread the lug nut to the stud. 4. Hold the axle hub/flange while tightening the lugnut. Draw the stud into position. 5. Remove the lug nut and washers. CAUTION Ensure that the stud is fully seated. 6.
Page 551 Exploded view of the drum, axle flange and stud 3. Remove the brake drum from the axle shaft flange. 4. Remove the brake shoes if necessary to provide clearance. Removing stud with C-clamp and socket 5. Use a large C-clamp and socket to press the stud from the axle flange.
Page 552 To Install: 1. Clean the stud hole with a wire brush. 2. Start the lug stud through the bore in the axle flange. Installing lug stud 3. Place approximately four flat washers over the stud and thread the lug nut to the stud.
Page 553 9. Torque the lug nuts to specification. 10. Lower the vehicle.
Page 554: Wheel Alignment
Wheel Alignment WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. General Information Caster Looking at a vehicle from the side, caster angle describes the steering axis from front to rear.
Page 555 Camber Looking from the front of the vehicle, camber is the inward or outward tilt of the top of wheels. When the tops of the wheels are tilted in, this is negative camber; if they are tilted out, positive. In a turn a slight amount of negative camber helps maximize contact of the tire with the road.
Page 556 Toe-in Frame Misalignment Frame misalignment...
Page 557 There are two types of frames commonly used, the ladder frame or full length frame and the subframe. Both frames are isolated from the body using rubber isolators. The subframe does not run the full length of the vehicle. The subframe supports the engine and transaxle.
Page 558 Thrust Angles Thrust angle The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle. The thrust angle is the path that the rear wheels take. Ideally the thrust angle is geometrically aligned with the body centerline. If, for example, the toe-in on the left rear wheel is out of specification, it moves the thrust line off center.
Page 559 parking brake adjustment or the wheel alignment. The way in which a tire is built may produce lead. Rear tires do not cause lead. Torque Steer A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration.
Page 560 The struts should be inspected for wear or damage. The control arms should be checked for loose or worn bushings. The stabilizer shaft (sway bar) attachments should be checked for loose or missing components. The frame fasteners should be checked for proper torque. The frame insulators should be checked for wear or damage.
Page 561 BRAKES Precautions Before servicing the brake system, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing the brake system. Brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent.
Page 562 Cleanliness and Care, Shop Practice It should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. When any internal engine parts are serviced, care and cleanliness is important. When components are removed for service, they should be marked, organized or retained in a specific order for reassembly.
Page 563 All pistons employ some type of seal, usually made of rubber, to minimize fluid leakage. A rubber dust boot seals the outer end of the cylinder against dust and dirt. The boot fits around the outer end of the piston on disc brake calipers, and around the brake actuating rod on wheel cylinders.
Page 564 substitute a new lamp, make continuity checks, and, finally, replace the switch as necessary. The hydraulic system may be checked for leaks by applying pressure to the pedal gradually and steadily. If the pedal sinks very slowly to the floor, the system has a leak. This is not to be confused with a springy or spongy feel due to the compression of air within the lines.
Page 565 against the inner side of the drum. This action forces the bottoms of the two shoes to contact the brake drum by rotating the entire assembly slightly (known as servo action). When pressure within the wheel cylinder is relaxed, return springs pull the shoes back away from the drum.
Page 566 and flare. The replacement length of brake line is carefully bent to conform to the shape of the original brake line. One of the major causes of brake line replacement is twisting off or otherwise damaging a piece of brake line when replacing other components. For example, when replacing a rear wheel cylinder, if the brake line is rusted, loosening the brake line fitting backs the fitting over rusted portions of the brake line.
Page 567: Hydraulic Brake System
Hydraulic Brake System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Master Cylinder Reservoir Removal & Installation To Remove: Brake master cylinder assembly 1. Remove the brake master cylinder assembly from the power vacuum brake booster.
Page 568 Master cylinder reservoir 5. Remove the master cylinder reservoir from the brake master cylinder assembly. 6. Remove and discard the master cylinder reservoir seals from the brake master cylinder assembly. 7. Use denatured alcohol to clean the brake master cylinder assembly. 8.
Page 569 Brake Hoses and Steel Lines Removal & Installation To Remove: 1. Disconnect the negative battery cable. 2. Park the vehicle on a level surface. Place the vehicle in PARK (automatic) or REVERSE (manual) with the engine OFF, and apply the parking brake. Chock the rear wheels to prevent vehicle movement.
Page 570 Use two wrenches to loosen the fitting. If available, use flare nut type wrenches 8. Disconnect the other end of the line or hose, moving the drain pan if necessary. Always use a line wrench to avoid damaging the fitting. 9.
Page 571 Tape or plug the line to prevent contamination To Install: NOTE: Install the new line or hose, starting with the end farthest from the master cylinder. Connect the other end, and then confirm that both fittings are correctly threaded and turn smoothly using finger pressure.
Page 572 Master Cylinder Removal & Installation To Remove: 1. Apply the parking brake. 2. Disconnect the master cylinder fluid level sensor connector. 3. Remove the brake pipes from the master cylinder. CAUTION Install a rubber cap or plug to the exposed brake pipe ends to prevent brake fluid loss and contamination.
Page 573 To Install: 1. Bench bleed the master cylinder. 2. Attach the master cylinder assembly from the power vacuum brake booster. Torque the mounting nuts to 27 ft-lb (36 Nm). 3. Remove the plugs from the open brake pipe ends. 4. Install the brake pipes into the master cylinder. Torque the fittings to 24 ft-lb (32 Nm).
Page 574 Bench Bleeding CAUTION All new master cylinders should be bench bled prior to installation. It is very difficult to remove the air trapped in the master cylinder once it is installed on the vehicle. You will also introduce air into the vehicle’s hydraulic brake system. 1.
Page 575 Power Vacuum Brake Booster Removal & Installation To Remove: 1. Apply the parking brake. Brake master cylinder assembly 2. Remove the master cylinder assembly from the power vacuum brake booster. 3. Remove the power vacuum brake booster hose from the power vacuum brake booster and the engine.
Page 576 Stop lamp switch removal and installation 5. Disconnect the pushrod retainer from the brake pedal pin. 6. Remove the stop lamp switch and pushrod from the brake pedal pin. Brake booster removal and installation 7. Detach the power vacuum brake booster from the vehicle. 8.
Page 577 To Install: 1. Install the gasket onto the power vacuum brake booster. 2. For 2002 through 2004 vehicles, attach the power vacuum brake booster to the vehicle. Torque the mounting nuts to 30 ft-lb (40 Nm). 3. For 2005 through 2007 vehicles, attach the power vacuum brake booster to the vehicle.
Page 578 7. When bubbles cease to appear at the end of the bleeder hose, close the bleeder screw and remove the hose. 8. Check the fluid level in the master cylinder and add fluid accordingly. Do this after bleeding each wheel. 9.
Page 579: Disc Brakes
Disc Brakes WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Brake Caliper Removal & Installation Front To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. Brake caliper hose removal and installation 3.
Page 580 Brake caliper mounting bolts removal and installation 6. Detach the brake caliper from the mounting bracket. To Install: 1. Use denatured alcohol to clean the brake caliper guide pin bolts. 2. Use non-lubricated, filtered air to dry the brake caliper guide pin bolts. 3.
Page 581 Rear To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. Rear brake caliper hose removal and installation 3. Detach the brake caliper hose from the brake caliper. 4. To prevent excessive brake fluid loss, install a plug into the front brake caliper hose.
Page 582 Rear brake caliper removal and installation 6. Detach the brake caliper from the mounting bracket. To Install: 1. Use denatured alcohol to clean the brake caliper mounting bolts. 2. Use non-lubricated, filtered air to dry the brake caliper mounting bolts. 3.
Page 583 Overhaul To Disassemble: 1. Remove the caliper from the vehicle and place on a clean workbench. WARNING NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury! NOTE: Depending upon the vehicle, there are two different procedures to remove the piston from the caliper.
Page 584 Removing piston from caliper bore 4. For the second procedure, you must rotate the piston to retract it from the caliper. 5. If equipped, remove the anti-rattle clip. Removing anti-rattle clip...
Page 585 6. Use a pry tool to remove the caliper boot, being careful not to scratch the housing bore. Prying edge of boot Removing boot from caliper...
Page 586 8. Remove the piston seals from the groove in the caliper bore. Removing piston seal 9. Carefully remove the brake bleeder valve cap and valve from the caliper housing. 10. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
Page 587 To Assemble: 1. Lubricate and install the bleeder valve and cap. 2. Install the new seals into the caliper bore grooves, making sure they are not twisted. 3. Lubricate the piston bore. 4. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
Page 588 Bleeding caliper...
Page 589 Brake Rotor Removal & Installation Front To Remove: 1. Make sure the fluid level in the brake master cylinder reservoir is between the MIN and MAX level. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. Front C-clamp installation 4.
Page 590 Front brake rotor removal and installation 10. Remove the brake rotor from the wheel hub. 11. Use a J 42450-A wheel hub cleaning kit to clean the contact surface of the front hub. To Install: 1. Align the brake rotor to the marks on the wheel stud. 2.
Page 591 Rear C-clamp installation 4. Install a large C-clamp over the brake caliper housing and against the back of the outboard brake pad. 5. Tighten the clamp until the brake caliper is pushed in enough to slide the brake caliper from the rotor. 6.
Page 592 Rear brake rotor removal and installation 10. Remove the brake rotor from the wheel hub. 11. If necessary, use a J-46277 rotor removal tool and J 2619-01 slide hammer to remove the brake rotor from the wheel hub. 12. Use a J 42450-A wheel hub cleaning kit to clean the contact surface of the hub. 13.
Page 593 Brake Pads Removal & Installation Front To Remove: 1. Make sure the fluid level in the brake master cylinder reservoir is between the MIN and MAX level. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. Front C-clamp installation 5.
Page 594 Brake caliper mounting bolt removal and installation 7. Remove the lower mounting bolt from the brake caliper. Brake caliper...
Page 595 8. Lift the bottom of the brake caliper out of the mounting bracket. Outboard brake pad removal and installation 9. Remove the outboard brake pad from the brake caliper.
Page 596 Inboard brake pad removal and installation 10. Remove the inboard brake pad from the brake caliper.
Page 597 Brake pad shim removal and installation 11. Remove and discard the brake pad retaining clips from the brake caliper mounting bracket. 12. Use denatured alcohol to clean the brake caliper. To Install: 1. Install the new brake pad retaining clips into the brake caliper mounting bracket. 2.
Page 598 Rear To Remove: 1. Make sure the fluid level in the brake master cylinder reservoir is between the MIN and MAX level. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. Rear C-clamp installation 4. Install a large C-clamp over the brake caliper housing and against the back of the outboard brake pad.
Page 599 Rear brake pad removal and installation 9. Remove the brake pads from the brake caliper. 10. Remove the brake pad retaining clips from the brake caliper mounting bracket. 11. Use denatured alcohol to clean the brake caliper. To Install: 1. Install the brake pad retaining clips into the brake caliper mounting bracket. 2.
Page 600: Parking Brake
Parking Brake WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Brake Shoes Removal & Installation To Remove: 1. If applied, release the parking brake. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. 4.
Page 601 9. Remove and discard the parking brake shoe from the baking plate, over the axle flange. 10. Use a clean towel to clean the debris and dust from the parking brake components. 11. Turn the adjustment screw until it is in the fully home position in the notched adjustment nut, and then turn it in the opposite direction ¼...
Page 602 Adjustment 1. Remove the rotor from the rear hub. Brake rotor measurement 2. Adjust a J 21177-A drum to brake shoe clearance gage until it contact the inside diameter of the rotor. Brake shoe measurement...
Page 603 3. Place the J 21177-A drum to brake shoe clearance gage over the parking brake shoe lining at the widest point. 4. Turn the adjuster nut until the lining comes into contact with the J 21177-A drum to brake shoe clearance gage. 5.
Page 604 Parking Brake Actuator Removal & Installation To Remove: 1. Disable the parking brake cable adjuster. 2. Lift the vehicle. 3. Remove the wheel from the vehicle. 4. Remove the parking brake cable from the mounting bracket. 5. Remove the parking brake cable from the parking brake actuator lever. 6.
Page 605 To Install: 1. Apply GM P/N 12345493 threadlocker to the threads of the park brake actuator bolts. 2. Attach the park brake actuator to the backing plate. Torque the bolts to 100 ft-lb (135 Nm). 3. Install the parking brake shoe into the backing plate. 4.
Page 606 Parking Brake Cables Removal & Installation To Remove: 1. Disable the parking brake cable adjuster. 2. Lift the vehicle. 3. Remove the rear propeller shaft from the vehicle. Parking brake equalizer 4. Remove the parking brake cables from the parking brake equalizer.
Page 607 J 37043 5. Use a J 37043 parking brake cable release tool to remove the parking brake cables from the frame retainers. 6. Place a pole jack with a wooden block under the fuel tank. 7. Remove the fuel tank shield from the fuel tank. 8.
Page 608 Under body mounting studs 10. Detach the parking brake cables from the underbody mounting studs. Park brake cable retainers 11. Remove the parking brake cables from the retainers.
Page 609 Parking brake frame retainer 12. Detach the parking brake cable retainers from the frame. 13. Remove the parking brake from the mounting bracket. 14. Remove the parking brake cables from the parking brake actuators. 15. Remove the parking brake cables from the vehicle. To Install: 1.
Page 610 8. Attach the parking brake cable retainers to the frame. Torque the bolts to 15 ft-lb (20 Nm). 9. Install the parking brake cables into the retainers. 10. Install the fuel tank shield onto the fuel tank. 11. Install the parking brake cables into the parking brake equalizer. 12.
Page 611 Anti-Lock Brake System WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Electronic Brake Control Module Removal & Installation To Remove: 1. Disconnect the electronic brake control module (EBCM) connectors. Brake pressure modulator valve (A), Electronic brake control module (B), Brake pressure modulator vale bracket (C), Brake pressure modulator valve retaining bolts (D)
Page 612 To Install: 1. For 2002 through 2005 vehicles, attach the electronic brake control module (EBCM) from the brake pressure modulator valve (BPMV). Torque the new T-25 TORX® screws to 39 in-lb (5 Nm). 2. For 2006 through 2007 vehicles, attach the electronic brake control module (EBCM) from the brake pressure modulator valve (BPMV).
Page 613 Brake Pressure Modulator Valve Removal & Installation To Remove: 1. Disconnect the electronic brake control module (EBCM) connectors. 2. Disconnect the brake pipes from the brake pressure modulator valve (BPMV). Brake pressure modulator valve (A), Electronic brake control module (B), Brake pressure modulator vale bracket (C), Brake pressure modulator valve retaining bolts (D) 3.
Page 614 To Install: 1. For 2002 through 2005 vehicles, attach the electronic brake control module (EBCM) from the brake pressure modulator valve (BPMV). Torque the new T-25 TORX® screws to 39 in-lb (5 Nm). 2. For 2006 through 2007 vehicles, attach the electronic brake control module (EBCM) from the brake pressure modulator valve (BPMV).
Page 615 Front Wheel Speed Sensor Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3. Remove the brake rotor from the hub. 4. Remove the wheel speed sensor harness from the frame and control arm retainers. 5.
Page 616 6. Detach the wheel speed sensor from the hub. To Install: 1. Attach the wheel speed sensor to the hub. Torque the screw to 13 ft-lb (18 Nm). 2. Connect the wheel speed sensor connector. NOTE: If installing a new wheel speed sensor, the harness will have retainers already installed on it.
Page 617 Rear Wheel Speed Sensor Removal & Installation To Remove: 1. Lift the vehicle. 2. Disconnect the wheel speed sensor connector. Rear wheel speed sensor 3. Remove the wheel speed sensor from the sensor boss. To Install: 1. Make sure the wheel speed sensor and sensor boss are clean. 2.
Page 618 Wheel Speed Sensor Ring Removal & Installation To Remove: 1. Lift the vehicle. 2. Remove the wheel from the vehicle. 3. Remove the wheel speed sensor from the wheel. 4. Remove the rear axle housing cover from the rear axle. 5.
Page 619 To Install: Wheel speed sensor ring installation 1. Use a J 45860 and J 8092 to install the wheel speed sensor ring into the rear axle housing. J 23690 and J 8092 Installation 2. Use a J 23690 and J 8092 to install the axle shaft bearing into the rear axle housing.
Page 620 J 21128 Installation 3. Use a J 21128 to install the axle shaft seal into the rear axle housing. 4. Install the rear axle shaft into the vehicle. 5. Install the rear axle housing cover onto the rear axle housing. 6.
Page 621 AIR CONDITIONING & HEATING SYSTEMS Service Precautions CAUTION By law; in the manner as recommended by the manufacturer, only certified HVAC technicians can legally perform operations that involve installation and/or the removal/recovery of vehicle refrigerant. This is true of any and all operations that involve the potential exposure of vehicle refrigerant into the atmosphere.
Page 622 Do not open a cooling system when the engine is at running temperature. Personal injury can result. Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight.
Page 623 CAUTION By law only certified HVAC technicians can legally perform operations that involve installation and/or the removal/recovery of vehicle refrigerant. This is true of any and all operations that involve the potential for releasing of refrigerant into the atmosphere. General Troubleshooting Leak Testing WARNING Never leak test the A/C system with compressed air.
Page 624 Manifold gauge set components Refrigerant recovery/recycling station...
Page 625 Refrigerant Recovery & Recharging NOTE: It is not possible to determine the amount of refrigerant in an A/C system without completely evacuating the system and recharging it. Always refer to the underhood heating and air conditioning specification tag for the proper amount of refrigerant. CAUTION Do not add more refrigerant to the system than specified by the manufacturer.
Page 626 Odor Correction The air conditioning system may emit odors under certain conditions. This is usually due to the growth of mold on the evaporator and in the evaporator case. Water vapor from the air condenses on the fins of the evaporator as the A/C system is operating and collects in the evaporator housing.
Page 627 Troubleshooting by Symptom Poor Heater System Performance CAUTION Check all fluid levels and adjust as needed, before operating vehicle for extended periods at idle. 1. Start the engine. 2. Idle the engine until the thermostat opens (upper radiator hose will be hot) Is the engine at normal operating temperature (approx.
Page 628 Insufficient Defrosting CAUTION Check all fluid levels and adjust as needed, before operating vehicle for extended periods at idle. 1. Start the engine, select the DEFROST mode, and select the maximum blower speed. Does sufficient air flow from the defroster outlets? If yes, go to the next step.
Page 629 4. Listen to the blower motor at each blower speed. Is the blower motor making a squeaking or chirping noise? If yes, go to step 8. If no noise exists, go to step 10. 5. Remove the blower motor, and inspect the blower motor and impeller for deposits of foreign material.
Page 630 13. Idle the engine in PARK with the A/C compressor clutch engaged. Using a stethoscope, move around the entire A/C system testing for any abnormal noises caused by a component. Do any of the A/C components cause an abnormal noise? If yes, go to step 20.
Page 631 10. Install the components removed in step 5. When complete, go to the next step. 11. Operate the system to verify the repair. If system operates without noise, the repair is complete. If noise still exists, repeat the entire procedure.
Page 632 HVAC Control Module Removal & Installation To Remove: 1. Remove the accessory trim plate from the instrument panel. HVAC control module removal and installation 2. Remove the retaining screws from the HVAC control module. 3. Remove the HVAC control module from the instrument panel (I/P) by depressing the retaining tabs.
Page 633 Accumulator Removal & Installation To Remove: 1. Recover the refrigerant from the A/C system. 2. Disconnect A/C low pressure switch connector. 3. Remove the A/C low pressure switch from the accumulator. Accumulator removal and installation 4. Remove the accumulator retaining nut from the evaporator. 5.
Page 634 Air Door Actuators Removal & Installation Console Mode To Remove: 1. Remove the center console from the vehicle. 2. Detach the air outlet duct from the center console. 3. Disconnect the console mode actuator connector. 4. Detach the console mode actuator from the center console. To Install: 1.
Page 635 Left Side Air Temperature To Remove: 1. Remove the instrument panel carrier from the instrument panel. 2. Disconnect the left side air temperature actuator connector. HVAC control module - left side 3. Detach the left side air temperature actuator from the HVAC module.
Page 636 To Install: 1. Attach the left side air temperature actuator to the HVAC module. Torque the screw to 17 in-lb (1.9 Nm). 2. Connect the left side air temperature actuator connector. 3. Install the instrument panel carrier onto the instrument panel. 4.
Page 637 3. Detach the mode actuator from the HVAC module. To Install: 1. If installing a new mode actuator, move the mode door to the middle position. 2. Attach the mode actuator to the HVAC module. Torque the screw to 17 in-lb (1.9 Nm).
Page 638 Recirculation To Remove: 1. Remove the HVAC module from the instrument panel. 2. Detach the air inlet assembly from the HVAC module. Recirculation actuator removal and installation 3. Disconnect the recirculation actuator connector. 4. Detach the recirculation actuator from the HVAC module. To Install: 1.
Page 639 Front Auxiliary Blower Motor Removal & Installation To Remove: 1. For Buick and Saab vehicles, remove the instrument panel (I/P) from the vehicle. 2. For all vehicles except Buick and Saab, remove the center console from the vehicle. Auxiliary blower motor removal and installation 3.
Page 640 Rear Auxiliary Blower Motor Removal & Installation To Remove: 1. Remove the right rear quarter trim panel from the vehicle. Rear auxiliary HVAC module removal and installation 2. Detach the rear auxiliary HVAC module from the right side and floor of the vehicle.
Page 641 Rear auxiliary blower motor 3. Disconnect the rear auxiliary blower motor connectors. 4. Detach the rear auxiliary blower motor from the rear auxiliary HVAC module. To Install: 1. Attach the rear auxiliary blower motor to the rear auxiliary HVAC module. Torque the screws to 18 in-lb (2 Nm).
Page 642 Blower Motor Removal & Installation To Remove: 1. Remove the right insulator panel from the instrument panel (I/P). 2. Remove the storage compartment door from the instrument panel (I/P). 3. Disconnect the blower motor connector. Blower motor removal and installation 4.
Page 643 To Install: 1. Install the blower motor into the HVAC module. 2. Connect the cooing tube to the blower motor. 3. Install the mounting screws into the blower motor. Torque the screws to 18 in-lb (2 Nm). 4. Connect the blower motor connector. 5.
Page 644 Blower Motor Control Processor Removal & Installation Automatic HVAC To Remove: 1. Remove the right insulator panel from the instrument panel. 2. Disconnect the blower motor connector. Blower motor control processor removal 3. Disconnect the blower motor control processor connector. 4.
Page 645 To Install: 1. Attach the blower motor control processor from the HVAC module. Torque the screws to 17 in-lb (1.9 Nm). 2. Connect the blower motor control processor connector. 3. Connect the blower motor connector. 4. Install the right insulator panel onto the instrument panel.
Page 646 Blower Motor Resistor Assembly Removal & Installation To Remove: 1. Remove the right insulator panel from the instrument panel. 2. Disconnect the blower motor resistor assembly connector. 3. Detach the blower motor resistor assembly from the HVAC module. To Install: 1.
Page 647 A/C Compressor Removal & Installation 4.2L Engine To Remove: 1. Recover the refrigerant from the A/C system. 2. Remove the generator from the engine. 3. Remove the idler pulley from the engine. 4. Disconnect the a/c compressor connector. 5. Detach the a/c compressor hose assembly block from the a/c compressor. A/C compressor removal and installation (4.2L)
Page 648 6. Detach the a/c compressor from the engine. 7. Drain the oil from the a/c compressor and measure the amount of oil. To Install: 1. Refill the a/c compressor with the amount of oil drained. 2. Attach the a/c compressor to the engine. Torque the bolts to 37 ft-lb (50 Nm). 3.
Page 649 7. Remove the upper a/c compressor mounting bolts from the bracket. 8. Remove the lower coolant hose from the engine compartment. 9. Lift the vehicle. 10. Disconnect the a/c compressor connector. 11. Remove the lower a/c compressor mounting bolts from the bracket. 12.
Page 650 Condenser Removal & Installation To Remove: 1. Recover the refrigerant from the A/C system. 2. Detach the compressor discharge hose from the condenser. 3. Remove the hood latch from the vehicle. 4. Remove the headlamp housing panel from the vehicle. 5.
Page 651 Evaporator Core Removal & Installation To Remove: 1. Remove the HVAC module from the instrument panel carrier. 2. Remove the screws from the HVAC module. 3. Detach the top of the HVAC module from the bottom. Evaporator core 4. Remove the evaporator core from the HVAC module. 5.
Page 652 Front Heater Core Removal & Installation To Remove: 1. Remove the HVAC module from the instrument panel carrier. 2. Detach the heater core access cover from the HVAC module. Front heater core removal and installation 3. Remove the heater core from the HVAC module. To Install: 1.
Page 653 Rear Heater Core Removal & Installation To Remove: 1. Remove the rear auxiliary HVAC module from the vehicle. 2. Detach the heater core access cover from the rear auxiliary HVAC module. Rear heater core removal and installation 3. Remove the pass through seal from the auxiliary rear HVAC module. 4.
Page 654 Heater Inlet Hose Removal & Installation To Remove: 1. Drain the coolant from the engine. Heater hoses 2. Use a set of J 43181 heater line quick connect release tool to disconnect the heater inlet hose from the heater core inlet tube. 3.
Page 655 To Install: 1. Use engine coolant to lubricate the ends of the heater inlet hose. 2. Use a set of GE-47622 or J 38185 hose clamp pliers to connect the heater inlet hose to the engine block heater inlet hose fitting. 3.
Page 656 Front HVAC Module Removal & Installation To Remove: 1. Drain the coolant from the engine. 2. Recover the refrigerant from the A/C system. 3. Remove the instrument panel carrier from the instrument panel (I/P). 4. Use a J 43181 heater line quick connect release tool to removes the heater hoses from the heater core.
Page 657 8. Remove the HVAC module from the instrument panel (I/P). To Install: 1. If replacing the HVAC module, transfer any necessary components from the old module to the new module. 2. Install the HVAC module into the instrument panel (I/P). 3.
Page 658 Rear Auxiliary HVAC Module Removal & Installation To Remove: 1. Recover the refrigerant from the A/C system. 2. Drain the cooing system. 3. Lift the vehicle. Under vehicle rear auxiliary HVAC connections 4. Detach the a/c lines from the rear block fittings under the vehicle. 5.
Page 659 Rear auxiliary HVAC module removal and installation 12. Detach the rear auxiliary HVAC module from the right side and floor of the vehicle. 13. Remove and discard the pass through seal from the rear auxiliary HVAC module. To Install: 1. Install a new pass through seal onto the rear auxiliary HVAC module. 2.
Page 660 10. Attach the a/c lines to the rear block fittings under the vehicle. Torque the nuts to 15 ft-lb (20 Nm). 11. Lower the vehicle. 12. Refill the cooling system. 13. Evacuate and recharge the refrigerant in the A/C system. 14.
Page 661 6. For Oldsmobile vehicles, remove the shift lever bezel from the center console. 7. Remove the center console from the vehicle. 8. For GMC and Chevrolet vehicles, remove the lower sound insulator panel from the instrument panel (I/P). 9. For GMC and Oldsmobile vehicles, remove the accessory trim plate from the instrument panel (I/P).
Page 662 Lower instrument panel retaining volts 25. Remove the lower retaining bolts from the instrument panel (I/P)
Page 663 Upper instrument panel retaining volts 1. Remove the middle and upper bolts from the instrument panel (I/P). 2. Release the instrument panel (I/P) from the positioning locators by lifting up on the bottom of the instrument panel (I/P). 3. Remove the instrument panel (I/P) from the vehicle. 4.
Page 664 21. For GMC and Oldsmobile vehicles, install the accessory trim plate onto the instrument panel (I/P). 22. For GMC and Chevrolet vehicles, install the lower sound insulator panel onto the instrument panel (I/P). 23. Install the center console into the vehicle.
Page 665 Expansion (Orifice Tube) Removal & Installation To Remove: 1. Recover the refrigerant from the A/C system. 2. Remove the accumulator from the vehicle. 3. Remove the coolant reservoir from the vehicle. 4. Detach the evaporator tube from the evaporator. 5. Remove and discard the o-ring from the evaporator. 6.
Page 666 WARNING To avoid personal injury and/or vehicle damage, refer to the service precautions at the beginning of this section. Ambient Air Temperature Sensor Removal & Installation To Remove: 1. Remove the grille from the vehicle. Ambient air temperature sensor 2. Remove the ambient air temperature sensor from the panel assembly. 3.
Page 667 Inside Air Temperature Sensor Removal & Installation To Remove: 1. Remove the trim panel from the upper portion of the left B-pillar. Inside air temperature sensor removal and installation...
Page 668 2. Disconnect the inside air temperature sensor connector. 3. Detach the inside air temperature sensor assembly from the B-pillar. To Install: 1. Connect the inside air temperature sensor connector. 2. Attach the inside air temperature sensor assembly to the B-pillar. 3.
Page 669 A/C Refrigerant Pressure Sensor Removal & Installation To Remove: 1. Lift the vehicle. A/C refrigerant pressure sensor 2. Disconnect the a/c refrigerant pressure sensor connector. 3. Remove the a/c refrigerant pressure sensor from the compressor hose block. 4. Remove and discard the o-ring from the a/c refrigerant pressure sensor. To Install: 1.
Page 670 Sun Load Sensor Removal & Installation To Remove: 1. Remove the upper trim pad from the instrument panel (I/P). Sun load sensor removal and installation 2. Turn the sun load sensor counterclockwise and remove it from the upper trim pad. 3.
Page 671 Upper Left Air Temperature Sensor Removal & Installation To Remove: 1. Remove the radio and HVAC control module from the instrument panel (I/P). Upper air temperature sensors 1. Remove the upper left air temperature sensor from the upper air duct. 2.
Page 672 Lower Left Air Temperature Sensor Removal & Installation To Remove: 1. Remove the instrument panel from the vehicle. Lower left air temperature sensor 2. Disconnect the lower left air temperature sensor connector. 3. Remove the lower left air temperature sensor from the lower left air duct. To Install: 1.
Page 673 Upper Right Air Temperature Sensor Removal & Installation To Remove: 1. Remove the radio from the instrument panel (I/P). 2. Disconnect the upper right air temperature sensor connector. 3. Remove the upper right air temperature sensor from the upper air duct. To Install: 1.
Page 674 Lower Right Air Temperature Sensor Removal & Installation To Remove: 1. Remove the right insulator panel from the instrument panel (I/P). 2. Remove the lower insulator panel from the lower right air duct. 3. Disconnect the lower right air temperature sensor connector. Lower right air temperature sensor 4.
Page 675 A/C Low Pressure Switch Removal & Installation To Remove: 1. Disconnect the a/c low pressure switch connector. 2. Remove the a/c low pressure switch from the accumulator. 3. Remove and discard the o-ring from the accumulator. To Install: 1. Install a new o-ring onto the accumulator. 2.
Page 676 A/C Specifications...

Chevrolet Trailblazer Service Manual

Quick Links

Troubleshooting

Related Manuals for Chevrolet Trailblazer

Summary of Contents for Chevrolet Trailblazer

Table of Contents