Page 1 2007 SERVICE MANUAL JC636 99500S78J00-33E...
Page 2 Either of these two conditions may result in severe injury. • If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.
Page 3 Strict observance of the so specified items will enable one to obtain the full performance of the vehicle. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.
Page 5: Table Of Contents
TABLE OF CONTENTS Precautions..............00–i Transmission / Transaxle ...........5–i Precautions ............00–1 Automatic Transmission........5A–1 General Information ............0–i Steering ................6–i General Information ..........0A–1 Steering Wheel and Column ......... 6B–1 Maintenance and Lubrication ........ 0B–1 Power Assisted Steering System ......6C–1 Engine ................1–i HVAC ................7–i Engine General Information and Diagnosis ..
Page 7: Precautions
Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00–1 Road Test Caution ..........00–2 Work Stall Test Caution ........00–2 Precautions............00–1 Belt Dressing Notice........... 00–3 Definition of Caution, Notice, and Important ..00–1 Brake Fluid Effects on Paint and Approved Equipment for Electrical Components Notice ......
Page 8 Manual contain both general and specific Cautions, under repair Notices, and Importants. SUZUKI is dedicated to the presentation of service information that helps the • Damage to fasteners, basic tools, or special tools technician to diagnose and repair the systems •...
Page 9 Precautions: 00-2 Eye Protection Caution Road Test Caution WARNING WARNING Approved safety glasses and gloves should Road test a vehicle under safe conditions be worn when performing this procedure to and while obeying all traffic laws. Do not reduce the chance of personal injury. attempt any maneuvers that could jeopardize vehicle control.
Page 10 00-3 Precautions: Belt Dressing Notice Component Fastener Tightening Notice CAUTION CAUTION Do not use belt dressing on the drive belt. Replacement components must be the Belt dressing causes the breakdown of the correct part number for the application. composition of the drive belt. Failure to Components requiring the use of the thread follow this recommendation will damage the locking compound, lubricants, corrosion...
Page 11 Precautions: 00-4 OBDII Symbol Description Notice Test Probe Notice CAUTION CAUTION The OBD II symbol is used on the circuit Do not insert test equipment probes (DVOM diagrams in order to alert the technician that etc.) into any connector or fuse block the circuit is essential for proper OBD II terminal.
Page 12 00-5 Precautions:...
Page 13: Maintenance And Lubrication
Table of Contents 0- i Section 0 General Information CONTENTS General Information ....... 0A–1 Diagnostic Repair Verification - Vehicle Diagnostic Information....... 0A–58 General Description ..........0A–1 Symptoms - Vehicle Diagnostic Information ..0A–58 Abbreviations and Meanings......0A–1 Symptoms - Registered and Non-Registered Trademarks ..0A–6 Vibration Diagnosis and Correction....
Page 14: Charging System
0A-1 General Information: General Information General Description Abbreviations and Meanings Abbreviation Meaning Brake Pedal Position Abbreviation Meaning Brown BTDC Before Top Dead Center Ampere(s) Battery Thermal Module Antilock Brake System BTSI Brake Transmission Shift Interlock Air Conditioning British Thermal Units Alternating Current Accessory, Automatic Climate °C...
Page 15: Differential
General Information: 0A-2 Abbreviation Meaning Abbreviation Meaning Cylinder(s) Erasable Programmable Read Only EPROM Memory Delayed Accessory Bus Expansion Spring Brake Decibels Electronic Suspension Control Decibels on A-weighted Scale Electrostatic Discharge Direct Current, Duty Cycle Electronic Serial Number Door Control Module Electronic Throttle Control, Electronic Drive End Temperature Control, Electronic...
Page 16 0A-3 General Information: Abbreviation Meaning Abbreviation Meaning Heavy Duty LDCL Left Door Closed Locking Heavy Duty Cooling LDCM Left Door Control Module Hexagon, Hexadecimal Lamp Driver Module Mercury Light Emitting Diode Hi Alt High Altitude Low Emissions Vehicle HO2S Heated Oxygen Sensor Left Front Horsepower Lumens...
Page 17 General Information: 0A-4 Abbreviation Meaning Abbreviation Meaning Oxidation Converter Catalytic Random Access Memory, Non- Opportunity Charge Station permanent memory device, memory Outside Diameter contents are lost when power is Output Drive Module removed. Odometer Retained Accessory Power Original Equipment Remote Activation Verification Original Equipment Manufacturer RCDLR Remote Control Door Lock Receiver...
Page 18 0A-5 General Information: Abbreviation Meaning Abbreviation Meaning Scan Tool Vacuum Delay Valve STID Station Identification Station ID Velocity S4WD Selectable Four-Wheel Drive Variable Effort Steering Switch Vacuum Fluorescent Short Wheel Base Violet SWPS Steering Wheel Position Sensor Vehicle Identification Number Synchronizer Voltage Loop Reserve Vacuum Modulator Valve...
Page 19 General Information: 0A-6 Registered and Non-Registered Trademarks GM Pass® Listed below are Registered Trademarks (®) or Non- GM Ultralite® GMAC® Registered Trademarks (™) which may appear in this service manual. Goodwrench® GTP® AC® Homelink™ ACCUTURN® HYDRA-MATIC® ACDelco® Active Fuel Management™ Illumination®...
Page 20 Seat, Front Bucket, Deluxe This service manual uses various symbols in order to Restraint, Roof Side, LH and RH, describe different service operations. Inflatable Merchandised Package, Suzuki XL-7 Touring Merchandised, Suzuki XL-7 Limited Plant Code Ingersol, Ontario, Canada Roof, Sun, Glass, Sliding, Electric...
Page 21 General Information: 0A-8 US English/Metric Conversion Description Wheel, 16 x 6.5 Steel Multiply/ Divide English Metric Tire All, P235/65R16 - 101S BW R/PE ST TL AL2 In order to calculate English measurement, divide by Tire All, P235/60R17 - 100S BW R/PE ST the number in the center column.
Page 22 0A-9 General Information: Decimal and Metric Equivalents Fraction (in) Decimal (in) Metric (mm) 59/64 0.921875 23.41562 Fraction (in) Decimal (in) Metric (mm) 15/16 0.9375 23.8125 1/64 0.015625 0.39688 61/64 0.953125 24.20937 1/32 0.03125 0.79375 31/32 0.96875 24.60625 3/64 0.046875 1.19062 63/64 0.984375 25.00312...
Page 23: Metric Fasteners
General Information: 0A-10 Fasteners Metric Fasteners This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material.
Page 24 0A-11 General Information: The metric fasteners on this vehicle is designed to new, international standards. The following are the common sizes and pitches, except for special applications: • M6.0 X 1 • M8 X 1.25 • M10 X 1.5 • M12 X 1.75 •...
Page 25 General Information: 0A-12 Metric Prevailing Torque Fastener Minimum Torque Development Specification Application Metric English All Metal Prevailing Torque Fasteners 6 mm 0.4 N⋅m 4 lb in 8 mm 0.8 N⋅m 7 lb in 10 mm 1.4 N⋅m 12 lb in 12 mm 2.1 N⋅m 19 lb in...
Page 26 0A-13 General Information: Thread Inserts General purpose thread repair kits. These kits are available commercially. Repair Procedure WARNING Refer to Safety Glasses Caution. NOTE Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips.
Page 27 General Information: 0A-14 Lifting and Jacking the Vehicle WARNING To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Page 28: Rear Suspension
The VIN plate (1) is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel and can be seen through the windshield from the outside of the vehicle. 1, 2, 3 Manufacturer 2 S 3 SUZUKI (Canada CAMI production) Line SUZUKI XL7 A: AWD Chassis Type...
Page 29 General Information: 0A-16 Position Definition Character Description 4--9 Plant Sequence Number — Plant Sequence Number A VIN derivative can be used to determine if a vehicle contains the original engine or transmission by matching the VIN derivative positions to their accompanying positions in the complete VIN. AF33-5 M09-M45 Transaxle ID and VIN Derivative Locations Refer to “Transmission Identification Information”.
Page 30 0A-17 General Information: Callout Description Vehicle Certification Label The vehicle certification label is located on the driver door and displays the following assessments: • Gross vehicle weight rating (GVWR) • Gross axle weight rating (GAWR), front and rear • The gross vehicle weight (GVW) is the weight of the vehicle and everything it carries. The GVW must not exceed the GVWR.
Page 31: Exhaust System
General Information: 0A-18 Vibration Theory and Terminology Vibration Theory The designs and engineering requirements of vehicles have undergone drastic changes over the last several years. Vehicles are stiffer and provide more isolation from road input than they did previously. The structures of today's stiffer vehicles are less susceptible to many of the vibrations which could be present in vehicles of earlier designs, however, vibrations can still be detected in a...
Page 32 0A-19 General Information: Basic Vibration Terminology The motion of the stick occurs in repetitive cycles. The cycle begins at midpoint, continues through the lowest The following are the 2 primary components of vibration extreme of travel, then back past the midpoint, through diagnosis: the upper extreme of travel, and back to the midpoint •...
Page 33 General Information: 0A-20 Cycle 1. 1st Cycle 3. 3rd Cycle 2. 2nd Cycle 4. Time Vibration Cycles in Powertrain Components 1. Spindle 2. Pinion Nose The word cycle comes from the same root as the word circle. A circle begins and ends at the same point, as thus, so does a cycle.
Page 34 0A-21 General Information: Frequency 1. Amplitude 3. Time in Seconds 2. Reference 4. 1 Second Frequency is defined as the rate at which an event occurs during a given period of time. With a vibration, the event is a cycle, and the period of time is 1 second. Thus, frequency is expressed in cycles per second. The proper term for cycles per seconds is Hertz (Hz).
Page 35 General Information: 0A-22 Centrifugal Force Due to an Imbalance 1. Location of Imbalance (Degrees) 2. Centrifugal Force Acting on Spindle A spinning object with an imbalance generates a centrifugal force. Performing the following steps will help to demonstrate centrifugal force: 1.
Page 36: Front Suspension
0A-23 General Information: Natural or Resonant Frequency Resonance The natural frequency is the frequency at which an 1. Frequency - cps object tends to vibrate. Bells, guitar strings, and tuning 2. Suspension Frequency forks are all examples of objects that tend to vibrate at 3.
Page 37 General Information: 0A-24 Damping 1. Low Damping 2. High Damping Damping is the ability of an object or material to dissipate or absorb vibration. The automotive shock absorber is a good example. The function of the shock absorber is to absorb or dampen the oscillations of the suspension system.
Page 38 0A-25 General Information: Beating (Phasing) Two separate disturbances that are relatively close together in frequency will lead to a condition called beating, or phasing. A beating vibration condition will increase in intensity or amplitude in a repetitive fashion as the vehicle travels at a steady speed.
Page 39: Parking Brake
General Information: 0A-26 An oval-shaped tire with 2 high spots would create a Ensure the following conditions are met before disturbance twice for every revolution. This is called programming a control module: second-order vibration. Three high spots would be third- •...
Page 40 0A-27 General Information: DTC Symptom Description - Vehicle Diagnostic Information A DTC symptom is a 2-digit number which adds additional detail to a DTC. The DTC symptom provides additional information without requiring a large increase in the number of new DTCs. DTC Symptom Categories The DTC symptom is made up of 2 alphanumeric digits.
Page 41 General Information: 0A-28 DTC Symptom Subtypes DTC Symptom DTC Symptom Description The second digit of the DTC symptom is the subtype of Missing Reference the DTC symptom. These subtypes and their categories, Reference Compare Error together with their definitions, are given in the following General Checksum Failure table.
Page 42: Engine Electrical Devices
0A-29 General Information: Service Materials (Lubricants, Oil, Grease, Sealant, Adhesive, Cleaner, etc) General Gm Part Gm Part NO. Standard Supplier Application Name Name • Crankshaft prelube GM P/N EOS Engine • Piston pin bores in the piston and 1052367 Lubricant Assembly Valspar the connecting rod...
Page 43 Application Name Name Automatic GM P/N MOBIL ATF transmission 88900925 3309 Exxon mobile Automatic transmission inner parts fluid (Canadian P/N SUZUKI ATF Type T- IV 22689186) 3317 GM P/N 12345382 Permatex® All seat belt fasteners Transmission Threadlocker Permatex (Canadian P/N...
Page 44 0A-31 General Information: General Gm Part Gm Part NO. Standard Supplier Application Name Name GM P/N Windshield 89021822 Accrapac/ Glass Cleaner Windshield cleaner (Canadian P/N Kemkrest 992727) Polyolefin High strength plastic Adhesion adhesive — Goodwrench, (Flexible plastic part) Promoter primer Various Body section Urethane...
Page 45 General Information: 0A-32 Component Location Engine Identification Vehicle Identification Number The Vehicle Identification Number (VIN) Derivative is located in one place on the engine and is a seventeen digit number stamped or laser etched onto the block at the vehicle assembly plant. If reading the identification number the following information can be obtained: •...
Page 46 0A-33 General Information: Transmission Identification Information 1. Transmission I.D. Location 7. Serial Number During the Month of Manufacture 2. Model Number 8. Assembly Line Code 3. I.D. Code 9. Model of Transaxle, V = 55-50SN 4. GM Part Number 10. Month of Manufacture, A = Jan, B = Feb, etc 5.
Page 47 General Information: 0A-34 Diagnostic Fault Information The diagnostic Fault Information table identifies each circuit that makes up an electrical subsystem and the associated circuit faults. DTCs and symptoms are listed in the table for all circuit fault modes. This information can be used to diagnose an electrical fault, or as a quick visual aid showing how the different symptoms and DTCs apply for the subsystem being diagnosed.
Page 48 0A-35 General Information: Circuit/System Verification When testing for individual circuit faults, the technician is expected to include terminal inspections such as The diagnostic format does not force a technician to any connection surfaces and terminal tension at both the of the 3 diagnostic categories (Circuit/System harness and component/module.
Page 49 General Information: 0A-36 Strategy Based Diagnosis - Vehicle Diagnostic Information The goal of Strategy Based Diagnostics is to provide guidance when you create a plan of action for each specific diagnostic situation. Following a similar plan for each diagnostic situation, you will achieve maximum efficiency when you diagnose and repair vehicles.
Page 50 0A-37 General Information: 3. Perform Published Diagnostic System Check: The Diagnostic System 5.5. Vehicle Operates as Designed: This condition exists when the vehicle is Check verifies the proper operation of the system. This will lead the found to operate normally. The condition described by the customer may technician in an organized approach to diagnostics.
Page 51: Trailering Package
General Information: 0A-38 1. Verify the Customer Concern: The first part of this step is to obtain as 5.3. No Published Diagnostics: Analyze the Concern. Develop a plan for the much information as possible from the customer. Are there aftermarket diagnostics.
Page 52 0A-39 General Information: Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information This master DTC list includes all applicable DTCs in alphanumeric order with descriptors. The GM LAN modules on this vehicle also support DTC Symptom information. Refer to “DTC Symptom Description - Vehicle Diagnostic Information”...
Page 53 General Information: 0A-40 Module that DTC Descriptor Diagnostic Procedure Sets the DTC B0285 Electric Rear Defrost Circuit Low “DTC B0285 or B0286: ” B0286 Electric Rear Defrost Circuit High “DTC B0285 or B0286: ” Temperature Control 1 Feedback “DTC B0228, B0413, B0423, B0433, B3779 or B0413 HVAC Circuit...
Page 54 0A-41 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC Navigation Display Head Backlighting Navigation B2474 “DTC B2474: ” Performance Radio B2508 Seat Heater Relay Circuit “DTC B2508 or B2509: ” B2530 Front Fog Lamp Control Circuit “DTC B2530: ” B2545 Backup Lamps Circuit “DTC B2545: ”...
Page 55 General Information: 0A-42 Module that DTC Descriptor Diagnostic Procedure Sets the DTC Unconfigured Transponder/Vehicle B3976 “DTC B3976: ” Configuration Not Programmed C0035 Left Front Wheel Speed Sensor Circuit EBCM “DTC C0035-C0050: ” Right Front Wheel Speed Sensor C0040 EBCM “DTC C0035-C0050: ” Circuit C0045 Left Rear Wheel Speed Sensor Circuit EBCM...
Page 56 0A-43 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC Crankshaft Position (CKP) - Intake P0016 Camshaft Position (CMP) Correlation “DTC P0016, P0017, P0018, or P0019: ” Bank 1 Crankshaft Position (CKP) - Exhaust P0017 Camshaft Position (CMP) Correlation “DTC P0016, P0017, P0018, or P0019: ”...
Page 57 General Information: 0A-44 Module that DTC Descriptor Diagnostic Procedure Sets the DTC P0100 Mass Air Flow (MAF) Sensor Circuit “DTC P0100, P0102, or P0103: ” Mass Air Flow (MAF) Sensor P0101 “DTC P0101: ” Performance Mass Air Flow (MAF) Sensor Circuit P0102 “DTC P0100, P0102, or P0103: ”...
Page 58 0A-45 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC HO2S Slow Response Bank 2 Sensor P0153 “DTC P0133 or P0153: ” HO2S Circuit Insufficient Activity Bank P0154 “DTC P0134 or P0154: ” 2 Sensor 1 HO2S Heater Performance Bank 2 P0155 “DTC P0135, P0141, P0155, or P0161: ”...
Page 59 General Information: 0A-46 Module that DTC Descriptor Diagnostic Procedure Sets the DTC “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0265 Injector 2 Control Circuit High Voltage ECM P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0267...
Page 60 0A-47 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC “DTC P0341, P0342, P0343, P0346, P0347, Intake Camshaft Position (CMP) P0341 P0348, P0366, P0367, P0368, P0391, P0392, Sensor Performance Bank 1 or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, Intake Camshaft Position (CMP) P0342 P0348, P0366, P0367, P0368, P0391, P0392,...
Page 61 General Information: 0A-48 Module that DTC Descriptor Diagnostic Procedure Sets the DTC Evaporative Emission (EVAP) Purge P0459 “DTC P0443, P0458, or P0459: ” Solenoid Control Circuit High Voltage P0461 Fuel Level Sensor 1 Performance “DTC P0461: ” Fuel Level Sensor 1 Circuit Low P0462 “DTC P0462: ”...
Page 62 0A-49 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC “DTC P0601, P0602, P0603, P0604, P0605, Control Module Random Access P0606, P0607, P1600, P1621, P1627, P1680, Memory (RAM) P0604 P1681, P1683, or P2610: ” Transmission Control Module (TCM) “DTC P0601, P0602, P0603, or P0604: ”...
Page 63 General Information: 0A-50 Module that DTC Descriptor Diagnostic Procedure Sets the DTC Cooling Fan Relays 2 and 3 Control “DTC P0480, P0481, P0691, P0692, P0693, or P0694 Circuit High Voltage P0694: ” P0698 5 Volt Reference 3 Circuit Low Voltage ECM “DTC P0698 or P0699: ”...
Page 64 0A-51 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC Shift Pressure Control (PC) Solenoid “DTC P0962, P0963, P0966, P0967, P0970, or P0970 Control Circuit Low Voltage P0971: ” Shift Pressure Control (PC) Solenoid “DTC P0962, P0963, P0966, P0967, P0970, or P0971 Control Circuit High Voltage P0971: ”...
Page 65 General Information: 0A-52 Module that DTC Descriptor Diagnostic Procedure Sets the DTC Intake Camshaft Position (CMP) “DTC P0010, P0013, P0020, P0023, P2088, P2092 Actuator Solenoid Control Circuit Low P2089, P2090, P2091, P2092, P2093, P2094, Voltage Bank 2 or P2095: ” Intake Camshaft Position (CMP) “DTC P0010, P0013, P0020, P0023, P2088, P2093...
Page 66 0A-53 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC Barometric Pressure (BARO) Sensor P2229 “DTC P2227, P2228, or P2229: ” Circuit High Voltage HO2S Signal Circuit Shorted to Heater P2231 “DTC P2231 or P2234: ” Circuit Bank 1 Sensor 1 HO2S Signal Circuit Shorted to Heater P2232 “DTC P2232 or P2235: ”...
Page 67 General Information: 0A-54 Module that DTC Descriptor Diagnostic Procedure Sets the DTC “DTC P0601, P0602, P0603, P0604, P0605, Control Module Ignition Off Timer P2610 P0606, P0607, P1600, P1621, P1627, P1680, Performance P1681, P1683, or P2610: ” P2636 Fuel Transfer Pump Flow Insufficient “DTC P2636: ”...
Page 68 0A-55 General Information: Module that DTC Descriptor Diagnostic Procedure Sets the DTC “DTC U2105-U2199 (Except U2142 and Lost Communications With U2106 EBCM U2143): ” “DTC U2105-U2199 (U2142 or U2143 Transmission Control System only): ” “DTC U2105-U2199 (Except U2142 and Lost Communications With Body U2107 EBCM U2143): ”...
Page 69 General Information: 0A-56 Diagnostic System Check - Vehicle 3. Determine if the customer's vibration concern is truly an abnormal condition or something that is Diagnostic Information potentially an operating characteristic of the vehicle. 1. Verify that none of the following preliminary 4.
Page 70 0A-57 General Information: 8. Attempt to start the engine. Verify the engine starts 4. Verify that the following DTCs are not set: U1814, B1428. and runs. ➢ If either of the DTCs are set, refer to “DTC U1814: ” ➢ If the engine does not start and run, refer to “Engine or “DTC B1428: ”.
Page 71: Data Communications
General Information: 0A-58 Diagnostic Repair Verification - Vehicle Driver Information and Entertainment Diagnostic Information • “Symptoms - Entertainment: ” • “Symptoms - Displays and Gages: ” 1. Install any components or connectors that have been removed or replaced during diagnosis. •...
Page 72 0A-59 General Information: Symptoms - Vibration Diagnosis and Correction NOTE Perform the following steps in sequence BEFORE using these symptom tables. 1. Begin the diagnosis of a vibration concern by reviewing “Diagnostic Starting Point - Vibration Diagnosis and Correction” to become familiar with the diagnostic process used to properly diagnose vibration concerns. 2.
Page 73 General Information: 0A-60 Vibration Symptoms that are Heard Typical Category Description Frequency Condition of Occurrence Area of Focus Range Usually heard as an interior noise Vehicle Speed Sensitive Go to “Vibration similar to the noise of a bowling Still occurs during coast down Analysis - Tire and ball rolling down an alley, deep in NEUTRAL...
Page 74 0A-61 General Information: Vibration Analysis - Road Testing Test Description The numbers below refer to the step numbers on the diagnostic table. Obtaining rotational speed for the components rotating at tire/wheel speed is critical to systematically eliminating specific vehicle component groups. These component rotational speeds can be generated by using the J 38792-VS Vibrate Software, or through calculating them manually.
Page 75 General Information: 0A-62 Step Action 1. Install a scan tool. Go to “Diagnostic System Check - 2. With the scan tool, bring up the Powertrain Control Module Go to Step 7 Vehicle Diagnostic data list and select Engine Speed. Information” Is the scan tool operating properly? Using the J 38792-A, Electronic Vibration Analyzer (EVA) 2 is the preferred method for gathering necessary vibration...
Page 76 0A-63 General Information: Step Action 1. Install the J 38792-A sensor, if available, to the component identified by the customer as most respondent to the vibration. If no component was identified, install the J 38792-A sensor, if available, to the steering column. You may have to move the sensor to other locations later.
Page 77 General Information: 0A-64 Step Action 1. Select a smooth, level road and slowly accelerate the vehicle up to the speed at which the disturbance occurs. 2. Decelerate and safely downshift by one gear range. Go to “Vibration Go to “Vibration Analysis - Hub and/or 3.
Page 78 0A-65 General Information: Specific Conditions Can Affect the Condition • Loose Mounting Brackets or Component Ground-Out Engine-driven accessories such as a generator, a Consider the following conditions which may not have power steering pump, or an air conditioning been present while attempts were made to duplicate the compressor could exhibit noise conditions due to vibration concern.
Page 79 General Information: 0A-66 Vibration Diagnostic Aids - Vibration Driveline Torque-Load Conditions An drive axle that has internal conditions such as Duplicated, Component Not Identified excessive runout of components, misalignment of NOTE components, imbalance, etc., can produce vibration concerns which may be transmitted into the propeller If you have not completed the Vibration shaft, or shafts.
Page 80: Propeller Shafts
0A-67 General Information: Vibration in Service-Stall Test (Non-Torque 12. If the vehicle is equipped with a multiple-piece propeller shaft, hold the vibration sensor of the J Sensitive) 38792-A up to the propeller shaft support bearing Special tool assembly, or assemblies to inspect for vibration. J 38792-A Electronic Vibration Analyzer (EVA) 2 13.
Page 81 General Information: 0A-68 12. If the vibration is not reproduced, reinstall the brake 7. Have an assistant start the vehicle. rotors and/or drums and the wheel/tire assemblies to 8. Place the transmission in the highest forward gear. put an additional load on the system. Perform steps 9.
Page 82 0A-69 General Information: Control Module Schematic Repair Instruction Programming and Setup Remote Control Door Lock “Remote Function “Remote Control Door Lock “Transmitter Programming: ” Receiver Schematics: ” Receiver Replacement: ” after RCDLR replacement Sunroof Control Module “Sunroof Control Module This device requires no “Sunroof Schematics: ”...
Page 83 General Information: 0A-70 Special Tools and Equipment Substitute Special Tool Table The substitute special tools below are usable instead of the special tools described in this manual. NOTE “—” indicates the substitute special tool is not available. Engine Special Tools Described in This Manual Substitute Special Tools EN-46119 09916-14521...
Page 84 0A-71 General Information: Suspension Special Tools Described in This Manual Substitute Special Tools J-45097 09913-75821 Rear Control Arm Bushing Bearing Installer Attachment Remover J-45400 09943-25010 Strut Spring Compressor Spring Compressor Driveline/Axle Special Tools Described in This Manual Substitute Special Tools DT-48074 09924-07710 Input and Output Shaft Seal...
Page 85 General Information: 0A-72 Special Tools Described in This Manual Substitute Special Tools J-33832 09913-75821 Output Shaft Seal Installer Bearing Installer Attachment J-8092 Driver Handle J-35910 09943-57010 Drive Axle Seal Clamp Pliers Band Compressor 09943-57021 Pliers, Low-Profile Clamp...
Page 86 0A-73 General Information: Transmission/Transaxle Special Tools Described in This Manual Substitute Special Tools J-23327 09926-96040 Clutch Spring Compressor Clutch Spring Compressor No.8 J-35582 09913-85210 Oil Pump Seal Installer Bearing Installer J-41236 09926-98350 Coast Clutch Spring Spring Compressor No.4 Compressor J-44809 09924-07730 Output Shaft Seal Installer Bearing Installer...
Page 87 General Information: 0A-74 Special Tools Described in This Manual Substitute Special Tools J-45000 09913-50121 Seal Remover Oil Seal Remover J-45124 09942-15511 Removal Bridge Sliding Hammer J-45160 09944-96011 Differential Bearing Race Bearing Outer Rase Remover Remover J-45161 09943-88211 Manual Shift Shaft Bearing Pinion Bearing Installer Replacer J-45164...
Page 88 0A-75 General Information: Special Tools Described in This Manual Substitute Special Tools J-45166 09900-20701 Dial Indicator Extension Rod Magnetic Stand - 8 inch J-45185 09900-22403 Bore Gage Set Small Bore Gauge (18-35 J-45186 09926-95420 Forward and Direct Clutch Clutch Spring Compressor Spring Compressor J-45187 09924-07730...
Page 89 General Information: 0A-76 Special Tools Described in This Manual Substitute Special Tools J-45200 09900-20607 Dial Indicator Set Dial Gauge 09900-20701 Magnetic Stand...
Page 90 0A-77 General Information: Steering Special Tools Described in This Manual Substitute Special Tools J-1859-A 09944-36011 Steering Wheel Puller Steering Wheel Remover J-22610 09943-57010 Keystone Clamp Pliers Band Compressor 09943-57021 Pliers, Low-Profile Clamp...
Page 91 General Information: 0A-78 HVAC Special Tools Described in This Manual Substitute Special Tools GE-47849 09991-06530 Clutch Remover Armature Plate Remover GE-47851 09951-15511 Armature Installer Magnet Clutch Installer J-37872 09991-06310 Universal Spanner Wrench Armature Plate Holder J-39400-A 09990-86012 Halogen Leak Detector Gas Leak Detector...
Page 92 0A-79 General Information: Electronic Vibration Analyzer (EVA) The vibration sensor of the J 38792-A is designed to pickup disturbances which primarily occur in the vertical Description and Operation plane, since most vibrations are felt in that same up-and- Special tool down direction.
Page 93 General Information: 0A-80 EVA Strobe Balancing Function EVA Display The J 38792-A can be used to identify the light spot on a propeller shaft IF the propeller shaft rotational speed is the dominant frequency of the vibration concern. The J 38792-A is equipped with a strobe light trigger wire which can be used with an inductive pickup timing light, J 38792-25, or equivalent included with the J 38792-KIT,...
Page 94 0A-81 General Information: Vibrate Software Description and Operation Due to the limited diagnostic capability, limited availability and increasing costs of the reed tachometer, The J 38792-VS, Vibrate Software, is a computer it is NOT recommended as the primary tool to use in software program which is designed to be used in diagnosing a vibration concern.
Page 95 General Information: 0A-82 Illustration Tool Number/Description Illustration Tool Number/Description J 38792-A J 8001 Electronic Vibration Dial Indicator Set Analyzer 2 J 23409 J 38792-VS Dial Indicator Extension - 7 Vibrate Software 5/8 in J 38792-20 J 23498-A 20-Foot Timing Light Driveshaft Inclinometer Power Cord Extension J 23498-20...
Page 96: Scheduled Maintenance
0B-1 Maintenance and Lubrication: Maintenance and Lubrication Scheduled Maintenance Maintenance Items The Normal Maintenance Replacement Parts information will only be found in the Owner's Manual. Refer to the Maintenance Schedule subsection of the Owner's Manual. You may be able to use the Search information function using the words Replacement Parts. Maintenance Schedule (North American Emissions) The Maintenance Schedule information will only be found in the Owner's Manual.
Page 97 Table of Contents 1- i Section 1 Engine CONTENTS Engine General Information and DTC P0135, P0141, P0155, or P0161 ..... 1A–92 DTC P0137, P0138, P0140, P0157, P0158, Diagnosis ..........1A–1 or P0160............1A–95 General Description ..........1A–1 DTC P0201, P0202, P0203, P0204, P0205, OBD System Description - P0206, P0261, P0262, P0264, P0265, P0267, Mode $06 Data Definitions.......
Page 98: Aux. Emission Control Devices
1- ii Table of Contents DTC P2122, P2123, P2127, P2128, Special Tools - or P2138............1A–156 Engine Controls - 3.6L (LY7)......1B–16 DTC P2176 ............ 1A–158 Engine Electrical Devices...... 1C–1 DTC P2177, P2179, P2187, or P2189 ... 1A–159 DTC P2178, 2180, P2188, or P2190 ..... 1A–162 Precautions............
Page 99 Table of Contents 1- iii Specifications............ 1C–34 Drive Belt Tensioner Diagnosis......1D–41 Fastener Tightening Specifications - Vibration Analysis - Engine ......1D–42 Engine Controls - 3.6L (LY7) ......1C–34 Vibration Analysis - Engine/Accessory Isolation ......1D–44 Special Tools and Equipment ......1C–34 Vibration Analysis - Engine Balance ....
Page 100 1- iv Table of Contents Primary Camshaft Drive Chain Guide Primary Camshaft Drive Chain Guide Replacement - Upper ........1D–100 Removal - Lower (Third Design) ....1D–146 Camshaft Position Actuator Replacement - Primary Camshaft Drive Chain Guide Bank 2 (Left Side) Exhaust ......1D–101 Removal - Lower (Fourth Design) ....
Page 101 Table of Contents 1- v Crankshaft Rear Oil Seal and Camshaft Position Actuator Installation - Housing Removal......... 1D–158 Right Side Exhaust (Fourth Design)..... 1D–275 Piston, Connecting Rod, and Camshaft Position Actuator Installation - Bearing Removal ......... 1D–159 Left Side Intake (Third Design) ....1D–276 Crankshaft and Bearings Removal ....
Page 102: Engine Lubrication System
1- vi Table of Contents Secondary Camshaft Drive Chain Guide Oil Pump Cleaning and Inspection ....1E–17 Installation - Right Side (Fourth Design) ..1D–309 Oil Pump Assemble.......... 1E–19 Secondary Camshaft Drive Chain Shoe Oil Filter Adapter Disassemble......1E–20 Installation - Right Side (Third Design) ..1D–310 Oil Filter Adapter Cleaning and Inspection..
Page 103: Fuel System
Table of Contents 1- vii Radiator Surge Tank Inlet Hose/ Alcohol/Contaminants-in-Fuel Diagnosis Pipe Replacement.......... 1F–31 (w/ Special Tool) ..........1G–31 Surge Tank Replacement ........ 1F–32 Repair Instructions ........... 1G–32 Radiator Inlet Hose Replacement ....1F–33 Fuel Pressure Relief (With J 34730-1A)... 1G–32 Radiator Outlet Hose Replacement ....
Page 104 1- viii Table of Contents DTC P0615 ............1I–10 Generator Noise Diagnosis ....... 1J–36 DTC P0616 ............1I–12 Engine Cranks Slowly ........1J–38 DTC P0617 ............1I–13 Battery Inspection/Test ........1J–38 Symptoms - Engine Electrical ......1I–14 Battery Electrical Drain/Parasitic Load Test ..1J–41 Starter Solenoid Does Not Click......
Page 105 Table of Contents 1- ix Specifications............ 1K–32 Special Tools and Equipment ......1K–32 Fastener Tightening Specifications - Tools and Equipment ........1K–32 Engine Mechanical - 3.6L (LY7)..... 1K–32 Special Tools - Engine Exhaust ....... 1K–32 Fastener Tightening Specifications - Engine Exhaust..........1K–32...
Page 106 1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis General Description OBD System Description - Mode $06 Data Definitions MODE $06 Data Self diagnostic Test value Description Range* Resolution* test item OBDIMID Rich to Lean Sensor 0.0000 to 7.9900 V 0.122 mv / bit Threshold Voltage Lean to Rich Sensor...
Page 107 Engine General Information and Diagnosis: 1A-2 Self diagnostic Test value Description Range* Resolution* test item OBDIMID Oxygen Sensor Heater Monitor Sensor Element Impedance 0 to 65535 Ohms 1 Ohms / bit Bank 1 Sensor 2 Oxygen Sensor Heater Monitor Sensor Element Impedance 0 to 65535 Ohms 1 Ohms / bit Bank 2 Sensor 1...
Page 108 1A-3 Engine General Information and Diagnosis: Self diagnostic Test value Description Range* Resolution* test item OBDIMID EWMA (Exponential Weighted Moving Average) — — misfire counts for last 10 driving cycles (calculated) Misfire counts for last/ current driving cycles — — (calculated) EWMA (Exponential Weighted Moving Average)
Page 109 Engine General Information and Diagnosis: 1A-4 Schematic and Routing Diagram Engine Controls Schematic Icons Icon Icon Definition CAUTION The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation.
Page 110 1A-5 Engine General Information and Diagnosis: Module Power, Ground, and MIL...
Page 111 Engine General Information and Diagnosis: 1A-6 5-Volt Reference...
Page 112 1A-7 Engine General Information and Diagnosis: Low Reference...
Page 113 Engine General Information and Diagnosis: 1A-8 Mass Air Flow and Engine Coolant Temperature Sensor...
Page 114 1A-9 Engine General Information and Diagnosis: Camshaft Position Sensors and Actuators...
Page 115 Engine General Information and Diagnosis: 1A-10 Heated Oxygen Sensors...
Page 116 1A-11 Engine General Information and Diagnosis: Throttle Actuator Control and Accelerator Pedal Position Sensor...
Page 117 Engine General Information and Diagnosis: 1A-12 Ignition Coils...
Page 118 1A-13 Engine General Information and Diagnosis: Knock Sensors and Crank Sensor...
Page 119 Engine General Information and Diagnosis: 1A-14 Fuel Injectors and Fuel Pump...
Page 120 1A-15 Engine General Information and Diagnosis: Evaporative Emissions and Fuel Tank Pressure Sensor...
Page 121 Engine General Information and Diagnosis: 1A-16 Controlled/Monitored Systems...
Page 122 1A-17 Engine General Information and Diagnosis: Engine Control Module Connector End Circuit Wire Color Function Views Generator Field Duty Engine Control Module (ECM) C1 Cycle Signal 31-32 — — Not Used Camshaft Position 5276 Intake Sensor (2) Camshaft Position D-GN 5273 Exhaust Sensor (1) CKP Sensor [1] Signal...
Page 123 Engine General Information and Diagnosis: 1A-18 Circuit Circuit Wire Color Function Wire Color Function 94-95 — — Not Used — — Not Used HO2S Heater Low OG/BK 1786 Park/Neutral Signal GY/WH 3113 Control - Bank 1 Sensor — — Not Used EVAP Canister Vent 1310 Solenoid Control...
Page 124 1A-19 Engine General Information and Diagnosis: Engine Controls Connector End Views Connector Part Information OEM: 7283-7526-30 Accelerator Pedal Position (APP) Sensor Service: 88988588 Description: 2-Way F (BK) Terminal Part Information Terminal/Tray: 7116-4026/11 Core/Insulation Crimp: E/1 Release Tool/Test Probe: 15313892/J-35616-18 (BK) Camshaft Position Actuator - Bank 1 Exhaust Circuit Wire Color...
Page 125 Engine General Information and Diagnosis: 1A-20 Camshaft Position Actuator - Bank 2 Exhaust Connector Part Information OEM: 7283-7526-30 Service: 88988588 Description: 2-Way F (BK) Terminal Part Information Terminal/Tray: 7116-4026/11 Core/Insulation Crimp: E/1 Release Tool/Test Probe: 15313892/J-35616-18 (BK) Camshaft Position Actuator - Bank 2 Intake Circuit Wire Color Function...
Page 126 1A-21 Engine General Information and Diagnosis: Camshaft Position Sensor - Bank 1 Intake Connector Part Information OEM: 1928403968 Service: 88988595 Description: 3-Way F Kompakt 2.8 Series Sealed (BK) Terminal Part Information Terminal/Tray: 1928498056/8 Core/Insulation Crimp: E/1 Release Tool/Test Probe: J-38125-561/J-35616- 4A (PU) Camshaft Position Sensor - Bank 2 Exhaust Circuit...
Page 127 Engine General Information and Diagnosis: 1A-22 Crankshaft Position (CKP) Sensor Engine Coolant Temperature Sensor Circuit Wire Color Function ECT Sensor Signal 2761 Low Reference Engine Oil Pressure (EOP) Switch Connector Part Information OEM: 89047365 Service: 88988337 Description: 3-Way F Sealed (GN) Terminal Part Information Terminal/Tray: 33467-0005/23 Core/Insulation Crimp: J/J...
Page 128 1A-23 Engine General Information and Diagnosis: Fuel Injector 1 Connector Part Information OEM: 1928404072 Service: 88988586 Description: 2-Way F (BK) Terminal Part Information Terminal/Tray: 1928498056/8 Core/Insulation Crimp: E/1 Release Tool/Test Probe: J-38125-561/J-35616- 4A (PU) Evaporative Emission Canister Purge Solenoid Circuit Wire Color Function Powertrain Main Relay...
Page 129 Engine General Information and Diagnosis: 1A-24 Fuel Injector 3 Fuel Injector 5 Connector Part Information Connector Part Information OEM: 15305086 OEM: 15305086 Service: 15306318 Service: 15306318 Description: 2-Way F Metri-Pack Series (BK) Description: 2-Way F Metri-Pack Series (BK) Terminal Part Information Terminal Part Information Terminal/Tray: See Terminal Repair Kit Terminal/Tray: See Terminal Repair Kit...
Page 130 1A-25 Engine General Information and Diagnosis: Fuel Pump and Sender Assembly - Primary Connector Part Information OEM: 12059595 Service: 88986451 Description: 3-Way F Metri-Pack 150 Series Sealed (BK) Terminal Part Information Terminal/Tray: See Terminal Repair Kit Core/Insulation Crimp: See Terminal Repair Kit Release Tool/Test Probe: See Terminal Repair Kit Fuel Tank Pressure (FTP) Sensor Circuit...
Page 131 Engine General Information and Diagnosis: 1A-26 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor Connector Part Information OEM: 12160482 Service: 88988598 Description: 4-Way F Metri-Pack 150 Series, Sealed (BK) Terminal Part Information Terminal/Tray: 12048074/2 Core/Insulation Crimp: E/1 Release Tool/Test Probe: 12094429/J-35616-2A (GY) Heated Oxygen Sensor - Bank 2 Sensor 1 Circuit...
Page 132 1A-27 Engine General Information and Diagnosis: Ignition Coil 1 Connector Part Information OEM: 15466325 Service: 88988737 Description: 4-Way F Global Terminal/150 (BK) Terminal Part Information Pins: A, D, B, C Terminal/Tray: 12191819/8 Core/Insulation Crimp: Pins A, D - 2/A Core/Insulation Crimp: Pins B, C - E/A Release Tool/Test Probe: 15315247/J-35616-2A (GY) Ignition Coil 2...
Page 133 Engine General Information and Diagnosis: 1A-28 Ignition Coil 4 Ignition Coil 5 Circuit Wire Color Function 1550 Ground 2129 Low Reference D-GN 2125 Ignition Control 5 PK/BK 5291 Ignition 1 Voltage Ignition Coil 6 Connector Part Information OEM: 15466325 Service: 88988737 Description: 4-Way F Global Terminal/150 (BK) Terminal Part Information Pins: A, D, B, C...
Page 134 1A-29 Engine General Information and Diagnosis: Terminal Part Information Connector Part Information Terminal/Tray: 1928498054/8 OEM: 13520906 Core/Insulation Crimp: E/1 Service: 19151493 Release Tool/Test Probe: J-38125-561/J-35616- 4A Description: 5-Way F GT 150 Sealed (BK) (PU) Terminal Part Information Pins: A, B, D, E, C Knock Sensor (KS) 1 Terminal/Tray: 12191819/8 Circuit...
Page 135 Engine General Information and Diagnosis: 1A-30 Component Location Engine Controls Component Views Near the Air Cleaner 1. Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 3. Air Cleaner Assembly 2. Cowl...
Page 136 1A-31 Engine General Information and Diagnosis: Above the Battery 1. Fuse Block - Underhood 3. Engine Control Module (ECM) 2. LF Strut Tower...
Page 137 Engine General Information and Diagnosis: 1A-32 Front of the Engine 1. Throttle Actuator Control (TAC) Module 5. Engine Coolant Temperature (ECT) Sensor 2. Ignition Coil 2 6. Starter 3. Ignition Coil 4 7. Knock Sensor (KS) 2 4. Ignition Coil 6 8.
Page 138 1A-33 Engine General Information and Diagnosis: Top of the Engine 1. Ignition Coil 5 11. Camshaft Position (CMP) Actuator Solenoid - Intake Bank 2 2. Fuel Injector 5 12. Camshaft Position (CMP) Sensor - Intake Bank 2 3. Fuel Injector 6 13.
Page 139 Engine General Information and Diagnosis: 1A-34 Rear if the Engine 1. Evaporative Emissions (EVAP) Canister Purge Solenoid 5. Knock Sensor (KS) 1 2. Throttle Actuator Control (TAC) Module 6. Crankshaft Position (CKP) Sensor 3. Ignition Coil 3 7. Ignition Coil 5 4.
Page 140 1A-35 Engine General Information and Diagnosis: Oxygen Sensors 1. Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 3. Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 2. Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 4. Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2...
Page 141 Engine General Information and Diagnosis: 1A-36 Pedal Assemblies 1. Brake Pedal Position Sensor 2. Accelerator Pedal Position (APP) Sensor...
Page 142 1A-37 Engine General Information and Diagnosis: Near the Rear Differential 1. Rear Differential Clutch Control Module 4. Fuel Sending Unit 2. Fuel Tank 5. Fuel Tank Pressure (FTP) Sensor 3. Evaporative Emissions (EVAP) Canister Vent Solenoid Valve...
Page 143 Engine General Information and Diagnosis: 1A-38 Diagnostic Information and Procedures Diagnostic Starting Point - Engine Controls Diagnostic Starting Point - Engine Electrical Begin the system diagnosis with “Diagnostic System Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Check - Vehicle Diagnostic Information: ”.
Page 144 1A-39 Engine General Information and Diagnosis: Scan Tool Output Additional Menu Description Control Selection(s) This function controls the idle speed override in 25 RPM, 100 RPM, and 500 RPM increments, from the base idle speed to 1,400 RPM. The scan tool initiates the test when the following conditions are Special Functions/ met: Engine Speed Control...
Page 145 Engine General Information and Diagnosis: 1A-40 Scan Tool Output Additional Menu Description Control Selection(s) This function controls the fuel pump relay. The normal commanded state is NONE. The scan tool initiates the test when the following conditions are met: Special Functions/ •...
Page 146 1A-41 Engine General Information and Diagnosis: Scan Tool Output Controls - Engine Electrical Scan Tool Output Additional Menu Description Control Selection(s) The engine control module (ECM) commands the generator OFF by removing the 5-volt reference signal from the L-terminal of the Engine Output Controls GEN L-Terminal voltage regulator when you select OFF.
Page 147 Engine General Information and Diagnosis: 1A-42 Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off 5-Volt Reference 1, 2, or 3 EVAP, IGN, IND, TAC, CH OK/Fault Circuit Status Reason for A/C A/C Disengage 1-8 History Cooling/HVAC...
Page 148 1A-43 Engine General Information and Diagnosis: Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off Desired Exh. CMP Bank 1 or Degree Varies Desired Idle Speed Eng, EVAP, CMP, CT, IND 0-7,000 RPM 650 RPM Desired Int.
Page 149 Engine General Information and Diagnosis: 1A-44 Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off FC Relay 1 Circuit Status OK/Fault/Indeterminate FC Relay 2 and 3 Circuit OK/Fault/Indeterminate Status FC Relay 1 Command On/Off Varies...
Page 150 1A-45 Engine General Information and Diagnosis: Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off Int. CMP Bank 1 or 2 0-99% Varies Command Int. CMP Solenoid Bn. 1 or 2 OK/Fault/Indeterminate Circuit Status Knock Detected Cyl.
Page 151 Engine General Information and Diagnosis: 1A-46 Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off TCM Requested Torque Trans N⋅m/lb ft Varies TCM Torque Increase CT, TAC, Trans Yes/No TCS Torque Increase CT, TAC Yes/No...
Page 152 1A-47 Engine General Information and Diagnosis: Scan Tool Parameter Data List Units Displayed Typical Data Value Ignition ON/Engine Running Data Display/ Charging Parasitic Current Amps 0.0 Amps Info Data Display/ Charging Prev. State of Charge Info Data Display/ Charging Start Up State of Charge Info Data Display/ Charging State of Charge...
Page 153 Engine General Information and Diagnosis: 1A-48 Scan Tool Data Definitions - Engine Air Fuel Ratio: This parameter displays the ratio of air to fuel as calculated by the control module based on Controls - 3.6L (LY7) various sensor inputs. The scan tool will display a The Scan Tool Data Definitions list contains a brief lower air fuel ratio when a richer air to fuel mixture is description of all of the engine related parameters that...
Page 154 1A-49 Engine General Information and Diagnosis: Calc. TWC Temp. Bank 1 or Bank 2: This parameter Cylinder 1-6 Injector Circuit Status: This parameter displays the catalytic converter temperature as displays the state of the fuel injector control circuit. calculated by the control module. The parameter displays Fault if the fuel injector Catalytic Converter Protection Active: This control circuit is open, shorted to ground, or shorted...
Page 155 Engine General Information and Diagnosis: 1A-50 Engine Off EVAP Test Conditions Met: This EVAP Vent Solenoid Command: This parameter parameter displays Yes if the conditions for running displays the state of the control circuit for the Engine Off EVAP diagnostic are met. evaporative emission (EVAP) vent solenoid as Engine Off Time: This parameter displays the amount commanded by the control module.
Page 156 1A-51 Engine General Information and Diagnosis: Fuel Tank Level Remaining: This parameter displays HO2S Bank 1 or 2 Sensor 1 or 2 Heater Command: the amount of fuel in liters/gallons that remains in the This parameter displays the commanded state of the fuel tank as determined by the control module from Bank 2 Sensor 1 heater by the control module.
Page 157 Engine General Information and Diagnosis: 1A-52 Injector 1-6 Command: This parameter displays the Loop Status Bn. 1 or 2 Sen. 1: This parameter amount of fuel injector ON time or pulse width as displays the state of the fuel control system as commanded by the control module.
Page 158 1A-53 Engine General Information and Diagnosis: Misfire Current Cyl. 1-6: The scan tool displays a Start Up ECT: This parameter displays the temperature range of 0-200 counts. This parameter displays the of the engine coolant on start up based on input to number of misfires that have been detected during the control module from the ECT sensor.
Page 159 Engine General Information and Diagnosis: 1A-54 Total Knock Retard: This parameter indicates how VTD Auto. Learn Timer: This parameter indicates that much ignition spark timing is being retarded due to either the auto learn timer (used in the auto learn all control systems monitored by the control module.
Page 160 1A-55 Engine General Information and Diagnosis: Ignition 1 Signal: The scan tool displays 0-20 Volts. • The control module records the operating conditions The scan tool displays the voltage as received on the at the time the diagnostic fails. The first time the Ignition 1 circuit to the module.
Page 161 Engine General Information and Diagnosis: 1A-56 Non-Emissions Related DTCs Conditions for Running the DTC Action Taken When the DTC Sets - Type C • DTCs P0010, P0011, P0013, P0014, P0020, P0021, P0023, P0024, P0341, P0342, P0343, P0346, P0347, • The control module stores the DTC information into P0348, P0366, P0367, P0368, P0391, P0392, P0393, memory when the diagnostic runs and fails.
Page 162 1A-57 Engine General Information and Diagnosis: Reference Information DTC P0010, P0013, P0020, P0023, P2088, DTC Type Reference P2089, P2090, P2091, P2092, P2093, P2094, “Powertrain Diagnostic Trouble Code (DTC) Type or P2095 Definitions” Diagnostic Instructions Scan Tool Reference • Perform the “Diagnostic System Check - Vehicle •...
Page 163 Engine General Information and Diagnosis: 1A-58 Circuit/System Description Conditions for Clearing the DTC The camshaft position (CMP) actuator system enables DTCs P0010, P0013, P0020, P0023, P2088, P2089, the engine control module (ECM) to change the timing of P2090, P2091, P2092, P2093, P2094, and P2095 are the camshafts while the engine is operating.
Page 164 1A-59 Engine General Information and Diagnosis: Circuit/System Testing DTC P0011, P0014, P0021, or P0024 Diagnostic Instructions 1. Ignition OFF, disconnect the harness connector at the appropriate camshaft position (CMP) actuator • Perform the “Diagnostic System Check - Vehicle solenoid. Diagnostic Information: ” prior to using this diagnostic 2.
Page 165 Engine General Information and Diagnosis: 1A-60 Conditions for Setting the DTC Circuit/System Verification • The ECM detects the difference between the desired NOTE camshaft position and the actual camshaft position The engine oil level and the oil pressure are angle is more than 5 degrees. critical to the correct operation of the camshaft position (CMP) actuator system.
Page 166 1A-61 Engine General Information and Diagnosis: Repair Instructions 4. Connect a test lamp between the control circuit terminal 2 and B+. Perform the “Diagnostic Repair Verification - Vehicle Diagnostic Information: ” after completing the diagnostic 5. Command the appropriate CMP actuator solenoid procedure.
Page 167 Engine General Information and Diagnosis: 1A-62 Circuit/System Description Action Taken When the DTC Sets The camshaft position (CMP) actuator system enables DTCs P0016, P0017, P0018, and P0019 are type B the engine control module (ECM) to change the timing of DTCs.
Page 168 1A-63 Engine General Information and Diagnosis: Circuit/System Testing – A timing chain that jumped teeth – A crankshaft reluctor wheel that has moved in 1. Ignition ON, observe the DTC information with a relationship to top dead center (TDC) on the scan tool.
Page 169 Engine General Information and Diagnosis: 1A-64 Circuit Description Conditions for Setting the DTC The heated oxygen sensor (HO2S) heater reduces the P0030, P0036, P0050, and P0056 time required for the oxygen sensor to reach operating The ECM detects an open in the heater circuits of the temperature and maintains the operating temperature HO2S when the heater is commanded OFF.
Page 170 1A-65 Engine General Information and Diagnosis: Reference Information 3. Connect a test lamp between the heater control circuit terminal D and B+. The test lamp should not Schematic Reference illuminate. “Engine Controls Schematics” Connector End View Reference ➢ If the test lamp is always ON, test the control circuit for a short to ground.
Page 171 Engine General Information and Diagnosis: 1A-66 DTC P0100, P0102, or P0103 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 172 1A-67 Engine General Information and Diagnosis: Diagnostic Aids Circuit/System Testing • Inspect the harness of the MAF sensor to verify that it 1. Ignition OFF, disconnect the harness connector at is not routed too close to the following components: the MAF sensor. –...
Page 173 Engine General Information and Diagnosis: 1A-68 DTC P0101 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 174 1A-69 Engine General Information and Diagnosis: Reference Information 2. Ignition OFF, disconnect the harness connector at the MAF sensor. Schematic Reference “Engine Controls Schematics” CAUTION Connector End View Reference Do NOT use the low reference circuit in the • “Engine Control Module Connector End Views” component harness connector for this test.
Page 175 Engine General Information and Diagnosis: 1A-70 DTC P0111, P0112 or P0113 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 176 1A-71 Engine General Information and Diagnosis: Conditions for Setting the DTC Reference Information P0111 Schematic Reference The ECM detects that the IAT remains steady within 2°C “Engine Controls Schematics” (4°F) during the idle test. The condition exists for a total Connector End View Reference of 16 seconds.
Page 177 Engine General Information and Diagnosis: 1A-72 Component Testing 4. Test for less than 5 ohms between the low reference circuit terminal E and ground. 1. Ignition OFF, disconnect the harness connector of ➢ If greater than 5 ohms, test the low reference circuit the IAT sensor.
Page 178 1A-73 Engine General Information and Diagnosis: Circuit Description Conditions for Setting the DTC The engine coolant temperature (ECT) sensor is a • The ECM determines the difference between the ECT variable resistor that measures the temperature of the and IAT at ignition ON is not within 15°C (26°F) of the engine coolant.
Page 179 Engine General Information and Diagnosis: 1A-74 Reference Information NOTE Schematic Reference The control module or the sensor may be “Engine Controls Schematics” damaged if the circuit is shorted to battery Connector End View Reference positive voltage. • “Engine Control Module Connector End Views” 4.
Page 180 1A-75 Engine General Information and Diagnosis: DTC P0117 or P0118 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 181 Engine General Information and Diagnosis: 1A-76 • After starting a cold engine, the ECT sensor 3. Test for less than 1 volt between the low reference temperature should rise steadily, then stabilize after circuit terminal 2 and ground. the thermostat opens. ➢...
Page 182 1A-77 Engine General Information and Diagnosis: DTC P0119 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 183 Engine General Information and Diagnosis: 1A-78 • “Engine Controls Connector End Views” 3. Test for less than 1 volt between the low reference Electrical Information Reference circuit terminal 2 and ground. ➢ If greater than the specified value, test the low •...
Page 184 1A-79 Engine General Information and Diagnosis: DTC P0121, P0122, P0123, P0221, P0222, or P0223 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 185 Engine General Information and Diagnosis: 1A-80 Circuit/System Description Action Taken When the DTC Sets The throttle body assembly contains 2 throttle position • DTCs P0121 and P0221 are Type B DTCs. (TP) sensors. The TP sensors are mounted to the •...
Page 186 1A-81 Engine General Information and Diagnosis: Circuit/System Verification ➢ If less than the specified range, test the 5-volt reference circuit for a short to ground or an open/ 1. Ignition ON, observe the DTC information with a high resistance. If the circuit tests normal, replace scan tool.
Page 187 Engine General Information and Diagnosis: 1A-82 DTC P0125 or P0128 Conditions for Setting the DTC P0125 Diagnostic Instructions The actual ECT is not within 10°C (18°F) of the • Perform the “Diagnostic System Check - Vehicle calculated ECT after 2-5 minutes, which depends on the Diagnostic Information: ”...
Page 188 1A-83 Engine General Information and Diagnosis: Circuit/System Verification 3. Ignition ON, using a scan tool verify that the ECT sensor parameter is at −40°C (−40°F). 1. Verify that the engine coolant level is correct. ➢ If greater than −40°C (−40°F), test the signal circuit ➢...
Page 189 Engine General Information and Diagnosis: 1A-84 DTC P0131 or P0151 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 190 1A-85 Engine General Information and Diagnosis: Conditions for Setting the DTC Circuit/System Testing • The ECM detects that a primary HO2S voltage is less 1. Ignition OFF, disconnect the harness connector at than 60 mV while the corresponding secondary HO2S the appropriate HO2S sensor.
Page 191 Engine General Information and Diagnosis: 1A-86 DTC P0132 or P0152 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 192 1A-87 Engine General Information and Diagnosis: Conditions for Setting the DTC Circuit/System Testing The ECM detects that a primary HO2S voltage is greater 1. Ignition OFF, disconnect the harness connector at than 1,080 mV for greater than 4 seconds or for a the appropriate HO2S sensor.
Page 193 Engine General Information and Diagnosis: 1A-88 DTC P0133 or P0153 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 194 1A-89 Engine General Information and Diagnosis: Conditions for Setting the DTCs Circuit/System Testing The ECM determines that the length of time for a primary 1. Verify that none of the following conditions exist: HO2S to switch from lean to rich and back to lean, which –...
Page 195 Engine General Information and Diagnosis: 1A-90 DTC P0134 or P0154 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 196 1A-91 Engine General Information and Diagnosis: Conditions for Setting the DTCs Circuit/System Verification • A primary HO2S voltage is between 400-600 mV. 1. Engine idling, observe the HO2S voltage parameter. The voltage should fluctuate above and below the • The calculated internal resistance of a primary HO2S range of 350-550 mV.
Page 197 Engine General Information and Diagnosis: 1A-92 – Engine vacuum leaks 8. Verify that none of the following conditions exist: ➢ If you find any of the above conditions, repair as – The HO2S is loose necessary. – Lean or rich fuel injectors—Refer to “Fuel Injector Balance Test with Special Tool: ”...
Page 198 1A-93 Engine General Information and Diagnosis: Circuit Description • The engine is operating. The heated oxygen sensor (HO2S) heater reduces the • The ignition voltage is 10.5-18.1 volts. time required for the oxygen sensor to reach operating • The intake air temperature (IAT) is greater than −30°C temperature and maintains the operating temperature (−22°F).
Page 199 Engine General Information and Diagnosis: 1A-94 Circuit/System Verification Component Testing 1. Ignition OFF, disconnect the harness connector of NOTE the appropriate HO2S. It may take up to 8 minutes for the DTC to set. 2. Test the HO2S heater resistance for 3-35 ohms. ➢...
Page 200 1A-95 Engine General Information and Diagnosis: DTC P0137, P0138, P0140, P0157, P0158, or P0160 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 201 Engine General Information and Diagnosis: 1A-96 P0138, P0140, P0158, and P0160 Scan Tool Reference • The HO2S heater is at operating temperature. • “Scan Tool Data List - Engine Controls - 3.6L (LY7)” • The engine is operating for greater than 1 second. •...
Page 202 1A-97 Engine General Information and Diagnosis: – The HO2S is loose Repair Instructions Perform the “Diagnostic Repair Verification - Vehicle – Exhaust leaks near the HO2S Diagnostic Information: ” after completing the diagnostic – Engine vacuum leaks procedure. ➢ If you find any of the above conditions, repair as •...
Page 203 Engine General Information and Diagnosis: 1A-98 Circuit/System Description Reference Information The control module enables the appropriate fuel injector Schematic Reference on the intake stroke for each cylinder. Ignition voltage is “Engine Controls Schematics” supplied directly to the fuel injectors. The control module Connector End View Reference controls each fuel injector by grounding the control •...
Page 204 1A-99 Engine General Information and Diagnosis: ➢ If the test lamp does not illuminate and the fuse is 13. If all circuits/connections test normal, test or replace OK, repair the ignition voltage circuit for an open/ the appropriate fuel injector(s). high resistance between the multi-way connector and the fuse.
Page 205 Engine General Information and Diagnosis: 1A-100 Conditions for Running the DTC Conditions for Clearing the DTC DTCs P0300, P0301, P0302, P0303, P0304, P0305, • DTCs P0121, P0122, P0123, P0221, P0222, P0223, and P0306 are Type A (MIL flashing) or Type B1 DTCs. P0335, P0336, or P0338 are not set.
Page 206 1A-101 Engine General Information and Diagnosis: Circuit/System Verification 4. Remove the fuel pump fuse from the fuse block. 5. Install the J 26792 to the boot of the ignition coil and 1. Engine idling at the normal operating temperature. ground. ➢...
Page 207 Engine General Information and Diagnosis: 1A-102 DTC P0324 Conditions for Setting the DTC Diagnostic Instructions • The ECM detects an incorrect response to the self tests performed on the internal KS circuitry. • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ”...
Page 208 1A-103 Engine General Information and Diagnosis: DTC P0326, P0327, P0328, P0331, P0332, or Conditions for Running the DTCs P0333 P0326 and P0331 Diagnostic Instructions • Before the ECM can report DTC P0326 or P0331 failed, DTCs P0324, P0335, P0336, and P0338 must •...
Page 209 Engine General Information and Diagnosis: 1A-104 Diagnostic Aids 3. If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the conditions • Inspect the KS for physical damage. A KS that is for running the DTC. You may also operate the dropped or damaged may cause a DTC to set.
Page 210 1A-105 Engine General Information and Diagnosis: DTC P0335, P0336, or P0338 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 211 Engine General Information and Diagnosis: 1A-106 – The ECM uses the camshaft position sensors to 4. If the vehicle passes the Circuit/System Verification determine engine speed and position when there is test, then operate the vehicle within the conditions a CKP sensor condition. for running the DTC.
Page 212 1A-107 Engine General Information and Diagnosis: DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 213 Engine General Information and Diagnosis: 1A-108 P0343, P0348, P0368, P0393 Circuit/System Verification The CMP sensor signal voltage is always high and the 1. Ignition ON, observe the DTC information with a ECM detects no pulses from the CMP sensor for more scan tool.
Page 214 1A-109 Engine General Information and Diagnosis: Repair Instructions • The oxygen stored in the catalyst exceeds a calibrated threshold, which is determined from the Perform the Perform the “Diagnostic Repair Verification - rear HO2S signal. Vehicle Diagnostic Information: ” after completing the diagnostic procedure.
Page 215 Engine General Information and Diagnosis: 1A-110 Conditions for Setting the DTC Circuit/System Testing The ECM determines that the efficiency of the catalyst 1. Verify there are no HO2S or misfire DTCs set. has degraded below a calibrated threshold for more than ➢...
Page 216 1A-111 Engine General Information and Diagnosis: DTC P0442 • The fuel volatility is not excessive. Diagnostic Instructions • The ambient air temperature (AAT) is between 2-32°C (35-90°F). • Perform the “Diagnostic System Check - Vehicle • The intake air temperature (IAT) is between 2-32°C Diagnostic Information: ”...
Page 217 Engine General Information and Diagnosis: 1A-112 Reference Information 5. Activate the J 41413-200 and compare the flow meter's stable floating indicator position to the red Schematic Reference flag. The floating indicator should be below the red “Evaporative Emissions Hose Routing Diagram: ” flag.
Page 218 1A-113 Engine General Information and Diagnosis: Repair Instructions 7. Command the EVAP vent solenoid closed with a scan tool. • “Fuel Tank Pressure Sensor Replacement: ” 8. Use the remote switch to introduce smoke into the • “Evaporative Emission Canister Purge Solenoid Valve EVAP system.
Page 219 Engine General Information and Diagnosis: 1A-114 Conditions for Setting the DTC Circuit/System Verification P0443 1. Ignition ON, command the EVAP purge solenoid to The ECM detects the EVAP canister purge solenoid 50 % with a scan tool. You should hear an audible control circuit is open.
Page 220 1A-115 Engine General Information and Diagnosis: Component Testing Conditions for Running the DTC 1. Ignition OFF, disconnect the harness connector at • Before the ECM can report DTC P0446 failed, DTCs the EVAP purge solenoid. Test for 15-20 ohms of P0451, P0452, and P0453 must run and pass.
Page 221 Engine General Information and Diagnosis: 1A-116 Reference Information 5. Remove the fuel fill cap and connect the GE-41415- 50 to the fuel tank filler neck. Connect the J 41413- Schematic Reference 200 to the GE-41415-50. “Evaporative Emissions Hose Routing Diagram: ” Description and Operation 6.
Page 222 1A-117 Engine General Information and Diagnosis: DTC P0449, P0498, or P0499 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 223 Engine General Information and Diagnosis: 1A-118 Reference Information 2. Ignition ON, verify that a test lamp illuminates between the ignition voltage circuit terminal A and Schematic Reference ground. “Engine Controls Schematics” ➢ If the test lamp does not illuminate, test the ignition Connector End View Reference voltage circuit for a short to ground or an open/high •...
Page 224 1A-119 Engine General Information and Diagnosis: DTC P0451 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 225 Engine General Information and Diagnosis: 1A-120 Reference Information Special Tools Required Schematic Reference • J 41413-SPT High Intensity White Light “Engine Controls Schematics” • J 41413-VLV EVAP Port Vent Fitting Tool Connector End View Reference • J 41413-200 Evaporative Emissions System Tester •...
Page 226 1A-121 Engine General Information and Diagnosis: Typical Scan Tool Data FTP Sensor Circuit Short to Ground Open Short to Voltage Operating Conditions: Engine operating in Closed Loop at idle Parameter Normal Range: 0.2-4.8 V 5-Volt Reference FTP Sensor Signal Low Reference —...
Page 227 Engine General Information and Diagnosis: 1A-122 Circuit/System Testing Repair Instructions Perform the “Diagnostic Repair Verification - Vehicle 1. Ignition OFF, remove the fuse that supplies B+ to Diagnostic Information: ” after completing the diagnostic terminal C2-56 of the ECM. procedure. 2.
Page 228 1A-123 Engine General Information and Diagnosis: Conditions for Running the DTC Diagnostic Aids • Before the engine control module (ECM) can report • A fuel fill cap that is left OFF after a fuel fill, will cause DTC P0455 failed, DTCs P0443, P0451, P0452, this DTC to set.
Page 229 Engine General Information and Diagnosis: 1A-124 Circuit/System Verification Circuit/System Testing 1. Verify the following conditions do not exist in the Leak Testing EVAP system: NOTE – Loose, incorrect, missing, or damaged fuel fill cap • You must start with the Circuit/System –...
Page 230 1A-125 Engine General Information and Diagnosis: Component Testing 9. Use the remote switch to introduce smoke into the EVAP system. 1. Pressurize the EVAP system to 5 inches H20. 2. Compare the Fuel Tank Pressure sensor parameter NOTE with a scan tool to the J 41413-200 pressure/vacuum The fuel tank may need to be lowered to gage.
Page 231 Engine General Information and Diagnosis: 1A-126 Circuit Description Action Taken When the DTC Sets This DTC tests for continuous intake manifold vacuum DTC P0496 is a Type A/B DTC. flow to the Evaporative Emission (EVAP) System. The control module seals the EVAP system by commanding Conditions for Clearing the DTC the EVAP canister purge solenoid valve Closed and the DTC P0496 is a Type A/B DTC.
Page 232 1A-127 Engine General Information and Diagnosis: Repair Instructions Conditions for Running the DTC Perform the “Diagnostic Repair Verification - Vehicle P0506 and P0507 Diagnostic Information: ” after completing the diagnostic • DTCs P0111, P0112, P0113, P0116, P0117, P0118, procedure. P0119, P0121, P0122, P0123, P0221, P0222, P0223, •...
Page 233 Engine General Information and Diagnosis: 1A-128 Action Taken When the DTC Sets Circuit/System Testing DTCs P0506, P0507, and P050A are Type B DTCs. Engine operating, command the engine speed up to 1,400 RPM, down to 600 RPM, up to 1,400 RPM, and then exit using the scan tool.
Page 234 1A-129 Engine General Information and Diagnosis: Action Taken When the DTC Sets DTC P0562 Diagnostic Instructions • The ECM will command the charge indicator and or warning message to be illuminated on the instrument • Perform the “Diagnostic System Check - Vehicle panel cluster (IPC) and the driver information center Diagnostic Information: ”...
Page 235 Engine General Information and Diagnosis: 1A-130 Reference Information DTC P0563 Schematic Reference Diagnostic Instructions “Starting and Charging Schematics: ” • Perform the “Diagnostic System Check - Vehicle Connector End View Reference Diagnostic Information: ” prior to using this diagnostic “Engine Electrical Connector End Views: ” procedure.
Page 236 1A-131 Engine General Information and Diagnosis: Reference Information DTC Descriptors Schematic Reference DTC P0601: Control Module Read Only Memory (ROM) “Starting and Charging Schematics: ” DTC P0602: Control Module Not Programmed Connector End View Reference DTC P0603: Control Module Long Term Memory Reset “Engine Electrical Connector End Views: ”...
Page 237 Engine General Information and Diagnosis: 1A-132 Action Taken When the DTC Sets Circuit/System Verification • DTCs P0601, P0602, P0603, P0604, and P0606 are 1. Ignition ON, observe the DTC information with a Type A DTCs. scan tool. DTC P0602 or P0606 should not set. ➢...
Page 238 1A-133 Engine General Information and Diagnosis: Circuit/System Description Conditions for Clearing the DTC The engine control module (ECM) provides ignition DTCs P0627 and P0628 are Type C DTCs. voltage to the coil side of the fuel pump relay whenever DTC P0629 is a type B DTC. the engine is cranking or running.
Page 239 Engine General Information and Diagnosis: 1A-134 Circuit/System Testing Component Testing 1. Ignition OFF, disconnect the fuel pump relay. 1. Measure for 110-150 ohms of resistance between terminals 1 and 2 of the fuel pump relay. 2. Connect a test lamp between the control circuit of ➢...
Page 240 1A-135 Engine General Information and Diagnosis: Circuit/System Description P2100 The ECM detects the output circuit for the TAC motor is The engine control module (ECM) controls the throttle open, shorted to ground, or shorted to a voltage. valve by applying a varying voltage to the control circuits of the throttle actuator control (TAC) motor.
Page 241 Engine General Information and Diagnosis: 1A-136 Circuit/System Verification 2. Ignition OFF, disconnect the harness connector of the throttle body. Ignition ON, test for 4.0-4.1 volts 1. Ignition ON, observe the DTC information with a between the TAC motor control 1 circuit terminal B scan tool.
Page 242 1A-137 Engine General Information and Diagnosis: Circuit/System Description Circuit/System Verification The engine control module (ECM) has 3 5-volt reference 1. Ignition ON, observe the DTC information with a circuits. The ECM provides the 5-volt reference to scan tool. DTCs P0642 and P0643 should not set. various sensors.
Page 243 Engine General Information and Diagnosis: 1A-138 DTC P0650 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 244 1A-139 Engine General Information and Diagnosis: Circuit/System Testing Conditions for Running the DTC 1. If any other IPC indicators or gages are inoperative, • The ignition is ON for more than 3 seconds. refer to “Instrument Cluster Gages Inoperative: ”. •...
Page 245 Engine General Information and Diagnosis: 1A-140 Circuit/System Testing 3. Connect each component associated with the 5-volt reference 2 circuit one at a time while monitoring the NOTE 5-Volt Reference 2 Circuit Status parameter with a scan tool. The parameter should continue to display Additional DTCs will set when disconnecting the components.
Page 246 1A-141 Engine General Information and Diagnosis: Circuit/System Description Conditions for Clearing the MIL/DTC The engine controls (EC) ignition relay, or powertrain DTCs P0685, P0686, P0687, P0689, and P0690 are relay is a normally open relay. The relay switch is held in Type C DTCs.
Page 247 Engine General Information and Diagnosis: 1A-142 Circuit/System Testing 8. Connect a 15A fused jumper wire between the B+ supply voltage circuit and the ignition voltage circuit 1. Ignition OFF, disconnect the powertrain relay. of the powertrain relay. NOTE 9. Attempt to start the engine. The engine should start. The test lamp is used to load the circuit and ➢...
Page 248 1A-143 Engine General Information and Diagnosis: DTC P0698 or P0699 Reference Information Schematic Reference Diagnostic Instructions “Engine Controls Schematics” • Perform the “Diagnostic System Check - Vehicle Connector End View Reference Diagnostic Information: ” prior to using this diagnostic • “Engine Control Module Connector End Views” procedure.
Page 249 Engine General Information and Diagnosis: 1A-144 3. Connect each component associated with the 5-volt Conditions for Setting the DTC reference 3 circuit one at a time while monitoring the The ECM receives a serial data message, from the 5-Volt Reference 3 Circuit Status parameter with a TCM, in order to illuminate the MIL.
Page 250 1A-145 Engine General Information and Diagnosis: Conditions for Setting the DTC DTC P1011-P1014 The ECM receives no valid vehicle speed data from the Diagnostic Instructions TCM for more than 1 second. • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic Action Taken When the DTC Sets procedure.
Page 251 Engine General Information and Diagnosis: 1A-146 Conditions for Setting the DTC • Start the engine. Verify there is no abnormal engine The ECM detects that a CMP actuator is not in the noise during start up. parked position on an engine start-up. •...
Page 252 1A-147 Engine General Information and Diagnosis: Circuit/System Description DTC P1551 Correct engine misfire detection is dependent on Diagnostic Instructions whether or not the vehicle is experiencing a rough road • Perform the “Diagnostic System Check - Vehicle condition. A rough road condition causes unexpected Diagnostic Information: ”...
Page 253 Engine General Information and Diagnosis: 1A-148 Diagnostic Aids Circuit/System Verification • Operating the throttle valve with the Throttle Position 1. Ignition ON, observe the DTC information with a control function of the scan tool may cause additional scan tool. Verify that DTCs P0121, P0122, P0123, DTCs to set.
Page 254 1A-149 Engine General Information and Diagnosis: DTC P167D Diagnostic Aids If the condition is intermittent, move the related Diagnostic Instructions harnesses and connectors, with the engine operating, • Perform the “Diagnostic System Check - Vehicle while monitoring the circuit status for the component with Diagnostic Information: ”...
Page 255 Engine General Information and Diagnosis: 1A-150 DTC P2096 or P2098 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 256 1A-151 Engine General Information and Diagnosis: Conditions for Running the DTC Circuit/System Verification • Before the ECM can report DTC P2096 or P2098 1. Observe the HO2S voltage parameter with the engine running. The reading should fluctuate above failed, DTCs P0030, P0031, P0032, P0041, P0050, P0051, P0052, P0131, P0132, P0133, P0135, P0137, and below the range of 350-550 mV.
Page 257 Engine General Information and Diagnosis: 1A-152 DTC P2097 or P2099 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 258 1A-153 Engine General Information and Diagnosis: Conditions for Running the DTC Circuit/System Verification • Before the ECM can report DTC P2096 or P2098 1. Observe the HO2S voltage parameter with the failed, DTCs P0030, P0031, P0032, P0041, P0050, engine running. The reading should fluctuate above P0051, P0052, P0131, P0132, P0133, P0135, P0137, and below the range of 350-550 mV.
Page 259 Engine General Information and Diagnosis: 1A-154 DTC P2105 Conditions for Clearing the DTC DTC P2105 is a Type A DTC. Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Aids Diagnostic Information: ” prior to using this diagnostic •...
Page 260 1A-155 Engine General Information and Diagnosis: Circuit/System Testing Circuit/System Description The engine control module (ECM) controls the throttle 1. Ignition OFF, remove the fuse that supplies voltage valve by applying a varying voltage to the throttle to terminals C2-3, C2-5, and C2-6 of the ECM. Verify actuator control motor.
Page 261 Engine General Information and Diagnosis: 1A-156 DTC P2122, P2123, P2127, P2128, or P2138 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 262 1A-157 Engine General Information and Diagnosis: Circuit/System Description Diagnostic Aids The accelerator pedal assembly contains two Test the current out-put of the 5-volt reference circuits if accelerator pedal position (APP) sensors. The APP you suspect high resistance in the circuit. The current sensors are mounted in the pedal assembly and are not out-put should be greater than 80 mA for APP 1 and serviceable.
Page 263 Engine General Information and Diagnosis: 1A-158 Circuit/System Testing Component Testing 1. Ignition OFF, remove the fuse that supplies B+ to 1. Install a 3A fused jumper wire between the 5-volt reference terminal of the applicable APP sensor and terminal C2-56 of the ECM. 5 volts.
Page 264 1A-159 Engine General Information and Diagnosis: DTC P2177, P2179, P2187, or P2189 • The intake air temperature (IAT) is between 5-143°C (41-290°F). Diagnostic Instructions • The accelerator pedal position (APP) sensor angle is • Perform the “Diagnostic System Check - Vehicle less than 15 percent.
Page 265 Engine General Information and Diagnosis: 1A-160 Conditions for Setting the DTC • The throttle angle is less than 100 percent. P2177 or P2179 • The engine load is between 17-45 percent. The Total Fuel Trim Avg. is more than 23 percent for 4 •...
Page 266 1A-161 Engine General Information and Diagnosis: Circuit/System Verification – Leaking crankcase ventilation system – The engine control module grounds for being 1. If there are other DTCs set besides DTC P2177, clean, tight, and in the correct locations P2179, P2187, or P2189, refer to “Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic –...
Page 267 Engine General Information and Diagnosis: 1A-162 DTC P2178, 2180, P2188, or P2190 • The fuel system is in closed loop. Diagnostic Instructions • The engine is not in decel fuel cut-off (DEFCO). • The long term fuel trim is active. •...
Page 268 1A-163 Engine General Information and Diagnosis: Action Taken When the DTC Sets Circuit/System Testing DTCs P2178, P2180, P2188, and P2190 are Type B 1. Observe the LT FT Bn 1 and Bn 2 Cruise/Accel or DTCs. Idle/Decel parameters, in order to determine whether the rich condition is effecting only one bank of the Conditions for Clearing the MIL/DTC engine, or is common to both banks of the engine.
Page 269 Engine General Information and Diagnosis: 1A-164 DTC P2227, P2228, or P2229 Conditions for Setting the DTC Diagnostic Instructions P2227 • Perform the “Diagnostic System Check - Vehicle • The ECM detects that the BARO pressure is less than Diagnostic Information: ” prior to using this diagnostic 50 kPa or greater than 115 kPa.
Page 270 1A-165 Engine General Information and Diagnosis: Circuit/System Verification Circuit Description The engine control module (ECM) supplies a voltage 1. Start the engine. Observe the DTC information with a near 450 mV between the heated oxygen sensor scan tool. DTCs P2227, P2228, or P2229 should not (HO2S) signal circuit and the low reference circuit.
Page 271 Engine General Information and Diagnosis: 1A-166 Action Taken when the DTC Sets Circuit/System Verification DTCs P2231 and P2234 are Type B DTCs. 1. Ignition ON, observe the appropriate HO2S voltage parameter. The HO2S voltage parameter should be Conditions for Clearing the MIL/DTC less than 1,025 mV.
Page 272 1A-167 Engine General Information and Diagnosis: Circuit Description Reference Information The engine control module (ECM) supplies a voltage Schematic Reference near 450 mV between the heated oxygen sensor “Engine Controls Schematics” (HO2S) signal circuit and the low reference circuit. The Connector End View Reference HO2S varies the voltage over a range from about 1,000 •...
Page 273 Engine General Information and Diagnosis: 1A-168 DTC P2270 or P2272 Conditions for Running the DTC Diagnostic Instructions • Before the ECM can report DTC P2270 or P2272 failed, DTCs P0036, P0037, P0038, P0056, P0057, • Perform the “Diagnostic System Check - Vehicle P0058, P0137, P0138, P0140, P0141, P0157, P0158, Diagnostic Information: ”...
Page 274 1A-169 Engine General Information and Diagnosis: DTC Type Reference 4. Verify that none of the following conditions exist: “Powertrain Diagnostic Trouble Code (DTC) Type – Lean fuel injectors—Refer to “Fuel Injector Definitions” Balance Test with Special Tool: ” or “Fuel Injector Scan Tool Reference Balance Test with Tech 2: ”.
Page 275 Engine General Information and Diagnosis: 1A-170 DTC P2271 or P2273 Conditions for Running the DTC Diagnostic Instructions • Before the ECM can report DTC P2270 or P2272 failed, DTCs P0036, P0037, P0038, P0056, P0057, • Perform the “Diagnostic System Check - Vehicle P0058, P0137, P0138, P0140, P0141, P0157, P0158, Diagnostic Information: ”...
Page 276 1A-171 Engine General Information and Diagnosis: Reference Information Circuit/System Testing Schematic Reference 1. Engine operating, move the related HO2S “Engine Controls Schematics” harnesses for the appropriate rear sensor between Connector End View Reference the HO2S harness connector and the engine control •...
Page 277 Engine General Information and Diagnosis: 1A-172 DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 278 1A-173 Engine General Information and Diagnosis: Action Taken When the DTC Sets Circuit/System Testing DTCs P2300, P2301, P2303, P2304, P2306, P2307, 1. Ignition OFF, disconnect the harness connector at P2309, P2310, P2312, P2313, P2315, and P2316 are the appropriate ignition coil. Type B DTCs.
Page 279 Engine General Information and Diagnosis: 1A-174 DTC P2636 Action Taken When the DTC Sets DTC P2636 is a Type C DTC. Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Conditions for Clearing the MIL/DTC Diagnostic Information: ” prior to using this diagnostic DTC P2636 is a Type C DTC.
Page 280 1A-175 Engine General Information and Diagnosis: Symptoms - Engine Controls 3. Install a 3A fused jumper wire between the signal circuit terminal A and ground. Verify the scan tool Diagnostic Instructions Fuel Level Sensor-Left Tank voltage parameter is at • Perform the “Diagnostic System Check - Vehicle 0.0 volts.
Page 281 Engine General Information and Diagnosis: 1A-176 Rough, Unstable, or Incorrect Idle and Stalling: The – The operation of the transmission torque engine runs unevenly at idle. If severe, the engine or converter clutch (TCC)—The scan tool should the vehicle may shake. Engine idle may vary in indicate an engine speed drop when the TCC is speed.
Page 282 1A-177 Engine General Information and Diagnosis: – The thermostat is the correct heat range— Poor Fuel Economy Refer to “Thermostat Diagnosis: ”. • Heavy loads being carried or towed – Proper engine coolant level—Refer to “Draining • Acceleration rate too much or too often and Filling Cooling System (LY7 GE 47716 Fill): •...
Page 283 Engine General Information and Diagnosis: 1A-178 • There may be fuel spray at the fuel injectors and the Scan Tool Reference indicated fuel pressure may be correct, yet there may • “Scan Tool Data List - Engine Controls - 3.6L (LY7)” not be enough fuel to start the engine.
Page 284 1A-179 Engine General Information and Diagnosis: Inspection/Maintenance (I/M) System Check 6. Ignition ON, command the fuel pump ON with a scan tool. The fuel pressure should be between 380-410 Diagnostic Instructions kPa (55-60 psi). • Perform the “Diagnostic System Check - Vehicle ➢...
Page 285 Engine General Information and Diagnosis: 1A-180 Monitored Emission Control Systems Circuit/System Verification The OBD II system monitors all emission control Review the I/M System Status indicators. All I/M System systems that are on-board. Not all vehicles need every Status indicators should report YES. possible emission control system.
Page 286 1A-181 Engine General Information and Diagnosis: Inspection/Maintenance (I/M) Complete 2. Turn OFF all accessories; HVAC system, other electrical loads, including aftermarket/add-on System Set Procedure equipment, etc., and open the hood. Diagnostic Instructions 3. Set the vehicle parking brake and ensure the vehicle •...
Page 287 Engine General Information and Diagnosis: 1A-182 Inspection/Maintenance (I/M) System DTC Table System DTCs Required to Set System Status to YES If an I/M System Status indicator did NOT update to YES during the “Inspection/Maintenance (I/M) System Check”, review each indicator and reference this table to determine each DTC associated with the I/M System Status Indicator.
Page 288 1A-183 Engine General Information and Diagnosis: Specifications Temperature Versus Resistance - Engine Altitude Versus Barometric Pressure Coolant Temperature Sensor Barometric Altitude Altitude Pressure Resistance Resistance Temperature Measured in Measured in Measured in Minimum Maximum C°/F° Meters (m) Feet (ft) Kilopascals Ohms Ohms (kPa)
Page 289 Engine General Information and Diagnosis: 1A-184 Special Tools and Equipment Special Tools - Engine Controls - 3.6L (LY7) Illustration Tool Number/Description Illustration Tool Number/Description J 34730-405 CH 48096 Injector Test Lamp EVAP Service Access Port Tool J 35616 GM-Approved Terminal GE 41415-50 Test Kit Interrupted Thread Fuel...
Page 290 1A-185 Engine General Information and Diagnosis: Illustration Tool Number/Description J 41413-300 EVAP Cap and Plug Kit J 41413-SPT High Intensity White Light J 41413-VLV EVAP Service Port Vent Fitting...
Page 291: Evaporative Emission Control System
Aux. Emission Control Devices: 1B-1 Aux. Emission Control Devices Precautions Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice CAUTION Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: • The fuel pipe connections •...
Page 292 1B-2 Aux. Emission Control Devices: Purge Valve Leak Test Crankcase Ventilation System Description If the EVAP purge valve does not seal properly, fuel vapors could enter the engine at an undesired time, causing driveability concerns. The control module tests for this by commanding the EVAP purge valve OFF, closed;...
Page 293 Aux. Emission Control Devices: 1B-3 Schematic and Routing Diagram Emission Hose Routing Diagram 1. Evaporative Emission Purge Line 2. PCV Hose to Intake Manifold 3. Brake Booster Vacuum Hose 4. Crank Case Fresh Air Inlet...
Page 294 1B-4 Aux. Emission Control Devices: Evaporative Emissions Hose Routing Diagram 1. Secondary Fuel Tank Module 7. Fuel Filler Recirculation Pipe 2. Fuel Feed Pipe 8. Primary Fuel Tank Module and Fuel Limiter Vent Valve (FLVV) 3. Evaporative Emissions (EVAP) Canister Purge Pipe 9.
Page 295 Aux. Emission Control Devices: 1B-5 Repair Instructions Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure 4. Disconnect the EVAP pipe quick connect fitting (2) from the EVAP purge solenoid. Refer to “Plastic Collar Quick Connect Fitting Service: ”. 5. Remove the EVAP purge solenoid bracket bolt (3). 1.
Page 296 1B-6 Aux. Emission Control Devices: Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure 4. Connect the EVAP pipe quick connect fitting (1) to the EVAP purge solenoid. Refer to “Plastic Collar Quick Connect Fitting Service: ”. 1. Remove the evaporative emission (EVAP) canister. Refer to “Evaporative Emission Canister Replacement”.
Page 297 Aux. Emission Control Devices: 1B-7 Installation Procedure Evaporative Emission Canister Vent Hose Replacement Removal Procedure 1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to the released position. 1. Remove the fuel fill tube. Refer to “Filler Tube Replacement: ”.
Page 298 1B-8 Aux. Emission Control Devices: Evaporative Emission Pipe Replacement 3. Disconnect the evaporative emission (EVAP) pipe quick connect fitting (3) from the EVAP purge Removal Procedure solenoid. Refer to “Plastic Collar Quick Connect Fitting Service: ”. WARNING 4. Cap the fuel and EVAP lines in order to prevent Do not allow smoking or the use of open system contamination.
Page 299 Aux. Emission Control Devices: 1B-9 10. Disconnect the left rear brake line fitting from the 12. Remove the push pin (1) from the underbody side brake crossover pipe. rail hole. 13. With the aid of an assistant, release the fuel/EVAP/ brake pipe clips (2) from the underbody studs.
Page 300 1B-10 Aux. Emission Control Devices: Installation Procedure CAUTION 1. Install the EVAP feed pipe to the fuel/EVAP/brake Refer to “Fastener Notice: ”. pipe assembly clips. 4. Connect the right rear brake line fitting to the rear brake hose. Tightening torque Tighten the fitting to 18 N⋅m (13 lb ft).
Page 301 Aux. Emission Control Devices: 1B-11 6. Remove the caps from the fuel and EVAP lines. 11. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel feed pipe quick connect fitting (2) to 12. Connect the fuel feed pipe quick connect fitting (3) to the fuel tank.
Page 302 1B-12 Aux. Emission Control Devices: Evaporative Emission Canister Replacement Removal Procedure 4. Disconnect the EVAP canister purge hose/pipe (1) from the EVAP canister. 5. Remove the EVAP canister-to-underbody nuts (3). 6. Lower the EVAP canister. NOTE The EVAP emissions canister is located under the center of the vehicle.
Page 303 Aux. Emission Control Devices: 1B-13 Installation Procedure 5. Connect the EVAP canister vent hose/pipe (3) to the EVAP canister. Refer to “Plastic Collar Quick 1. Connect the EVAP vent solenoid electrical connector Connect Fitting Service: ”. (1). 6. Connect the EVAP canister fresh air hose/pipe to the 2.
Page 304 1B-14 Aux. Emission Control Devices: Evaporative Emission Canister Filter 7. Clean the inside of the EVAP canister filter housing with a clean shop towel. Replacement Removal Procedure Installation Procedure NOTE The evaporative emission (EVAP) canister filter cover must also be replaced when the EVAP filter is replaced to ensure proper operation of the EVAP canister.
Page 305 Aux. Emission Control Devices: 1B-15 Evaporative Emission System Cleaning Cleaning Procedure 1. Raise and support the vehicle. Refer to “Lifting and Special tool Jacking the Vehicle: ”. J 41413-200 Evaporative Emission System Tested 2. Remove the EVAP canister. Refer to “Evaporative Emission Canister Replacement”.
Page 306 1B-16 Aux. Emission Control Devices: Specifications Fastener Tightening Specifications - Engine Controls - 3.6L (LY7) Specification Application Metric English Evaporative Emission (EVAP) Canister Nut 9 N⋅m 80 lb in Evaporative Emission (EVAP) Purge Solenoid Bracket Bolt 10 N⋅m 89 lb in Left Rear Brake Line Fitting to Brake Crossover Pipe 18 N⋅m 13 lb ft...
Page 307 Engine Electrical Devices: 1C-1 Engine Electrical Devices Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen Sensor Resistance Learn Reset Notice CAUTION CAUTION Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen When replacing the HO2S perform the sensor (O2S).
Page 308 1C-2 Engine Electrical Devices: General Description Air Intake System Description The MAF sensor measures the amount of air coming into the engine. This direct airflow measurement is more accurate than the calculated airflow information obtained from the other sensor inputs. The MAF sensor also houses an integrated intake air temperature (IAT) sensor.
Page 309 Engine Electrical Devices: 1C-3 Camshaft Actuator System Description Camshaft Actuator System Overview 1. Camshaft Actuator Vane 9. Engine Oil Pressure Supply 2. Timing Chain Sprocket 10. Engine Oil Drain 3. Engine Oil Pressure-For retarding the camshaft 11. Engine Oil Pressure-For advancing the camshaft 4.
Page 310 1C-4 Engine Electrical Devices: Operation Change in Driving The CMP actuator assembly has an outer housing that is Camshaft Objective Result Condition driven by an engine timing chain. Inside the assembly is Position a rotor with fixed vanes that is attached to the camshaft. High RPM Retard Improve...
Page 311 Engine Electrical Devices: 1C-5 ECM Function ECM Service Precautions The ECM can supply 5 volts or 12 volts to the various The ECM, by design, can withstand the normal current sensors or switches. This is done through pull-up draws that are associated with the vehicle operations. resistors to the regulated power supplies within the However, care must be used in order to avoid overloading any of these circuits.
Page 312 1C-6 Engine Electrical Devices: Electrostatic Discharge (ESD) Damage • Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. NOTE • Inspect any hoses that are difficult to see. In order to prevent possible electrostatic • Inspect all of the wires in the engine compartment for discharge damage to the ECM, DO NOT touch the following conditions: the connector pins on the ECM.
Page 313 Engine Electrical Devices: 1C-7 Knock Sensor (KS) System Description The ECM monitors the driver demand for acceleration with 2 APP sensors. The APP sensor 1 signal voltage You can diagnose all of the sensors and most of the range is from about 0.98-4.16 volts as the accelerator input circuits with a scan tool.
Page 314 1C-8 Engine Electrical Devices: Throttle Body Relearn Procedure TAC System Default Actions/Reduce Power The engine control module (ECM) stores values that Modes include the lowest possible throttle position (TP) sensor There are 2 reduce power modes that the engine control positions—0 percent, the rest positions—7 percent, and module (ECM) can default to if an error is detected in the the return rate of both springs.
Page 315 Engine Electrical Devices: 1C-9 Repair Instructions Engine Coolant Temperature Sensor Installation Procedure Replacement Removal Procedure CAUTION Refer to “Fastener Notice: ”. 1. Disconnect the engine wiring harness electrical connector (4) from the engine coolant temperature 1. Install the ECT sensor. (ECT) sensor.
Page 316 1C-10 Engine Electrical Devices: Mass Airflow Sensor/Intake Air Temperature Installation Procedure Sensor Replacement Removal Procedure 1. Install the MAF/IAT sensor seal to the MAF/IAT sensor. 2. Install the MAF/IAT sensor to the air cleaner 1. Remove the air cleaner outlet duct. Refer to “Air assembly.
Page 317 Engine Electrical Devices: 1C-11 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure CAUTION Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully.
Page 318 1C-12 Engine Electrical Devices: Installation Procedure NOTE A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads.
Page 319 Engine Electrical Devices: 1C-13 • Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. • Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed.
Page 320 1C-14 Engine Electrical Devices: Heated Oxygen Sensor Replacement - Bank CAUTION 2 Sensor 1 Refer to “Fastener Notice: ”. Removal Procedure 2. Install the HO2S (2) to the catalytic converter. CAUTION Tightening torque Do not remove the pigtail from either the Tighten the sensor to 42 N⋅m (31 lb ft).
Page 321 Engine Electrical Devices: 1C-15 is to reinstalled, the threads must have anti- seize compound applied before the reinstallation. 1. Remove the fuel injector sight shield, if necessary. Refer to “Fuel Injector Sight Shield Replacement: ”. 2. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor 1.
Page 322 1C-16 Engine Electrical Devices: Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure CAUTION Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully.
Page 323 Engine Electrical Devices: 1C-17 Installation Procedure NOTE A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads.
Page 324 1C-18 Engine Electrical Devices: Heated Oxygen Sensor Wiring Repairs Accelerator Pedal Position Sensor Replacement Special tool Removal Procedure J-38125 Terminal Repair Kit CAUTION Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced.
Page 325 Engine Electrical Devices: 1C-19 6. Remove the APP assembly from the vehicle. 4. Connect the APP sensor harness connector. Push the connector in until the lock position is felt, then pull back to confirm engagement. Installation Procedure 5. Install the CPA to the APP sensor harness connector.
Page 326 1C-20 Engine Electrical Devices: Crankshaft Position Sensor Replacement Installation Procedure Removal Procedure 1. Install the crankshaft position sensor. 1. Raise and support the vehicle. Refer to “Lifting and CAUTION Jacking the Vehicle: ”. Refer to “Fastener Notice: ”. 2. If equipped with all wheel drive (AWD), remove the transfer case.
Page 327 Engine Electrical Devices: 1C-21 Camshaft Position Sensor Replacement - Installation Procedure Bank 1 (Right Side) Exhaust Removal Procedure 1. Install the CMP sensor. CAUTION 1. Remove the air cleaner assembly. Refer to “Air Refer to “Fastener Notice: ”. Cleaner Assembly Replacement: ”. 2.
Page 328 1C-22 Engine Electrical Devices: Camshaft Position Sensor Replacement - Installation Procedure Bank 1 (Right Side) Intake Removal Procedure 1. Install the CMP sensor. CAUTION 1. Remove the air cleaner assembly. Refer to “Air Refer to “Fastener Notice: ”. Cleaner Assembly Replacement: ”. 2.
Page 329 Engine Electrical Devices: 1C-23 Camshaft Position Sensor Replacement - Installation Procedure Bank 2 (Left Side) Exhaust Removal Procedure 1. Install the CMP sensor. CAUTION 1. Remove the air cleaner assembly. Refer to “Air Refer to “Fastener Notice: ”. Cleaner Assembly Replacement: ”. 2.
Page 330 1C-24 Engine Electrical Devices: Camshaft Position Sensor Replacement - Installation Procedure Bank 2 (Left Side) Intake Removal Procedure 1. Install the CMP sensor. CAUTION 1. Remove the air cleaner assembly. Refer to “Air Refer to “Fastener Notice: ”. Cleaner Assembly Replacement: ”. 2.
Page 331 Engine Electrical Devices: 1C-25 Camshaft Position Actuator Solenoid Valve Installation Procedure Solenoid Replacement - Bank 1 (Right Side) Intake Removal Procedure 1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary. 2. Install the CMP actuator solenoid valve. 1.
Page 332 1C-26 Engine Electrical Devices: Camshaft Position Actuator Solenoid Valve Installation Procedure Solenoid Replacement - Bank 1 (Right Side) Exhaust Removal Procedure 1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary. 2. Install the CMP actuator solenoid valve. 1.
Page 333 Engine Electrical Devices: 1C-27 Camshaft Position Actuator Solenoid Valve Installation Procedure Solenoid Replacement - Bank 2 (Left Side) Intake Removal Procedure 1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary. 2. Install the CMP actuator solenoid valve. 1.
Page 334 1C-28 Engine Electrical Devices: Camshaft Position Actuator Solenoid Valve Installation Procedure Solenoid Replacement - Bank 2 (Left Side) Exhaust Removal Procedure 1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary. 2. Install the CMP actuator solenoid valve. 1.
Page 335 Engine Electrical Devices: 1C-29 Knock Sensor Replacement - Bank 1 Removal Procedure 5. Loosen the knock sensor bolt and remove the knock sensor. 1. Raise and support the vehicle. Refer to “Lifting and Installation Procedure Jacking the Vehicle: ”. 2. Remove the rear exhaust manifold heat shield bolts and shield.
Page 336 1C-30 Engine Electrical Devices: Knock Sensor Replacement - Bank 2 Removal Procedure 2. Connect the engine wiring harness electrical connector (2) to the bank 1 knock sensor. 1. Raise and suitably support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”. 2.
Page 337 Engine Electrical Devices: 1C-31 Installation Procedure Engine Control Module Replacement CAUTION • Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent...
Page 338 1C-32 Engine Electrical Devices: NOTE It is necessary to record the remaining automatic transmission fluid life. If the replacement module is not programed with the remaining automatic transmission fluid life, the automatic transmission fluid life will default to 100 percent. If the replacement module is not programmed with the remaining automatic transmission fluid life, the automatic transmission fluid will need to...
Page 339 Engine Electrical Devices: 1C-33 Installation Procedure 3. Connect the engine wiring harness electrical connector (2) to the ECM. 1. Slide the ECM into the retainer until the clips (1) engage the ECM. 4. Connect the negative battery cable. Refer to “Battery Negative Cable Disconnection and Connection: ”.
Page 340 1C-34 Engine Electrical Devices: ECM Reprogramming 4. Engine Oil Life Remaining—When available, use a scan tool to reset the Engine Oil Life Remaining • If the ECM needs to be reprogrammed, refer to back to the original percentage recorded before the “Service Programming System (SPS): ”.
Page 341 Engine Mechanical: 1D-1 Engine Mechanical Precautions Torque Reaction Against Timing Drive Chain Notice CAUTION A wrench must be used on the hex of the camshaft when loosening or tightening in order to prevent component damage. Failure to prevent the torque reaction against the timing drive chain can lead to timing drive chain failure.
Page 342 1D-2 Engine Mechanical: Connecting Rods and Pistons The fourth design uses IT timing drive components on both the primary and secondary components. NOTE: The connecting rods are sinterforged steel and have full The pitch of the IT chain has changed therefore third and floating piston pins.
Page 343 Engine Mechanical: 1D-3 Right and Left Bank Designation The camshaft position actuator oil control valve (OCV) directs oil from the oil feed in the head to the appropriate Right hand (RH) and left hand (LH) designation through camshaft position actuator oil passages. There is one the engine mechanical section are viewed from the rear OCV for each camshaft position actuator.
Page 344 1D-4 Engine Mechanical: Replacing Engine Gaskets Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer Gasket Reuse and Applying Sealant Sealant Types • Do not reuse any gasket unless specified. • Gaskets that can be reused will be identified in the NOTE service procedure.
Page 345 Engine Mechanical: 1D-5 • The surfaces to be sealed must be clean and dry. • Do not overtighten the fasteners. • Use a RTV sealant bead size as specified in the – Apply the gasket eliminator sealant service procedure. evenly to get a uniform thickness of the gasket eliminator sealant on the sealing •...
Page 346 1D-6 Engine Mechanical: • Apply the pipe sealant bead to the inside of any bolt • Use a pipe sealant bead of the size or quantity as specified in the service procedure. hole areas. • Apply a continuous bead of pipe sealant to one CAUTION sealing surface.
Page 347 Engine Mechanical: 1D-7 Stage One 1. Left Intake Camshaft Position (CMP) Actuator Timing Mark - Circle 10. Left Primary Camshaft Intermediate Drive Chain Sprocket Timing Window for the Left Secondary Camshaft Timing Drive Chain Timing Link 2. Left Intake Secondary Camshaft Timing Drive Chain Timing Link 11.
Page 348 1D-8 Engine Mechanical: Stage Two 1. Left Intake Camshaft Position (CMP) Actuator Timing Mark - Circle 13. Crankshaft Sprocket Timing Mark 2. Left Intake Secondary Camshaft Timing Drive Chain Timing Link 14. Crankshaft Sprocket 3. Left Exhaust Secondary Camshaft Timing Drive Chain Timing Link 15.
Page 349 Engine Mechanical: 1D-9 Camshaft Timing Drive Chain Alignment Diagram (Fourth Design) Camshaft Position Actuator Timing Marks 1. Right Intake Camshaft Position Actuator Identifier 5. Exhaust Camshaft Position Actuator Identifier 2. Right Intake Camshaft Position Actuator Right Side Timing Mark - Triangle 6.
Page 350 1D-10 Engine Mechanical: Stage One 1. Left Intake Camshaft Position (CMP) Actuator Timing Mark - Circle 10. Left Primary Camshaft Intermediate Drive Chain Sprocket Timing Window for the Left Secondary Camshaft Timing Drive Chain Timing Link 2. Left Intake Secondary Camshaft Timing Drive Chain Timing Link 11.
Page 351 Engine Mechanical: 1D-11 Stage Two 1. Left Intake Camshaft Position (CMP) Actuator Timing Mark - Circle 13. Crankshaft Sprocket Timing Mark 2. Left Intake Secondary Camshaft Timing Drive Chain Timing Link 14. Crankshaft Sprocket 3. Left Exhaust Secondary Camshaft Timing Drive Chain Timing Link 15.
Page 352 1D-12 Engine Mechanical: Component Location Disassembled Views Engine Covers and Component Assemblies (1 of 2) 3. Engine Assembly 611. Exhaust Manifold Heat Shield Bolt 6. Intake Manifold Assembly 621. Right Exhaust Manifold Gasket 9. Left Camshaft Cover Assembly 622. Right Exhaust Manifold 10.
Page 353 Engine Mechanical: 1D-13 Engine Covers and Component Assemblies (2 of 2) 4. Engine Short Block Assembly 395. Coolant Pipe 7. Left Cylinder Head Assembly 396. Coolant Pipe O-ring 8. Right Cylinder Head Assembly 399. Coolant Pipe Bracket to Thermostat Housing Bolt 13.
Page 354 1D-14 Engine Mechanical: Camshaft Cover Assembly 250. Left Camshaft Cover 260. Left Camshaft Cover PCV Fitting 251. Left Camshaft Cover Gasket 261. Right Camshaft Cover PCV Fitting Orifice 252. Right Camshaft Cover 262. Oil Fill Tube 253. Right Camshaft Cover Gasket 263.
Page 355 Engine Mechanical: 1D-15 Camshaft Timing Components - Third Design 150. Crankshaft Sprocket 173. Left Secondary Timing Chain Shoe 151. Lower Primary Timing Chain Guide 174. Left Secondary Timing Chain Shoe Bolt 152. Primary Timing Chain Tensioner 175. Left Secondary Timing Chain Tensioner 153.
Page 356 1D-16 Engine Mechanical: Camshaft Timing Components - Fourth Design 150. Crankshaft Sprocket 173. Left Secondary Timing Chain Shoe 151. Lower Primary Timing Chain Guide 174. Left Secondary Timing Chain Shoe Bolt 152. Primary Timing Chain Tensioner 175. Left Secondary Timing Chain Tensioner 153.
Page 357: Intake Manifold
Engine Mechanical: 1D-17 Intake Manifold 283. Dirty PCV Hose 560. Fuel Rail 285. PCV Hose O-ring Outer/Larger 561. Fuel Injector 286. PCV Hose O-ring Inner/Smaller 562. Fuel Injector Retainer 295. Engine Coolant Air Bleed Pipe 563. Fuel Injector Upper Seal 296.
Page 358: Fuel Rail
1D-18 Engine Mechanical: Fuel Rail 532. Fuel Rail Bolt 564. Fuel Injector Lower Seal 560. Fuel Rail 565. Fuel Pressure Service Valve Cap 561. Fuel Injector 566. Fuel Pressure Service Valve 562. Fuel Injector Retainer 700. Fuel Injector Wiring Harness 563.
Page 359 Engine Mechanical: 1D-19 Cylinder Head Assemblies 300. Left Cylinder Head 325. Valve Spring 301. Right Cylinder Head 326. Valve Spring Cap 302. Left Cylinder Head Gasket 327. Valve Stem Key 303. Right Cylinder Head Gasket 328. Cylinder Head Camshaft Front Thrust Bearing Cap 310.
Page 360 1D-20 Engine Mechanical: Engine Front Cover 132. Engine Front Cover Locating Pin 364. Water Pump Pulley Bolt 350. Engine Front Cover 390. Crankshaft Balancer 351. Engine Front Cover Gasket 391. Crankshaft Balancer Bolt 352. Engine Front Cover Bolt 725. Camshaft Position Sensor 353.
Page 361 Engine Mechanical: 1D-21 Oil Pump - Second Design 151. Lower Primary Timing Chain Guide 468. Oil Pump Cover Bolt 154. Lower Primary Timing Chain Guide Bolt 470. Oil Pressure Relief Valve Bore Plug 463. Oil Pump Housing 471. Oil Pressure Relief Valve Spring 464.
Page 362 1D-22 Engine Mechanical: Engine Block Assembly 15. Piston and Connecting Rod Assembly 124. Crankshaft Upper Thrust Bearing #3 100. Engine Block 126. Engine Block Oil Gallery Expansion Plug - 14 mm 110. Crankshaft Bearing Cap 127. Engine Block Oil Gallery Threaded Plug - 14 mm 111.
Page 363 Engine Mechanical: 1D-23 Piston, Rings, Bearing and Connecting Rod 200. Connecting Rod 212. Piston Pin Retainer 201. Connecting Rod Bolt 213. Piston Upper Compression Ring 202. Connecting Rod Bushing 214. Piston Lower Compression Ring 203. Connecting Rod Bearing 215. Piston Oil Control Rail Ring 210.
Page 364 1D-24 Engine Mechanical: Oil Pan Assembly 400. Oil Pan 411. Oil Pan Baffle Scraper Bolt 405. Oil Pump Suction Pipe 412. Oil Pan Drain Plug 406. Oil Pump Suction Pipe Gasket 413. Oil Pan Drain Plug O-ring 407. Oil Pump Suction Pipe Bolt 420.
Page 365 Engine Mechanical: 1D-25 Oil Filter Adapter 440. Oil Filter Adapter 445. Oil Filter Fitting 441. Oil Filter Adapter Gasket 449. Oil Filter 442. Oil Filter Adapter Bolt 728. Engine Oil Pressure Sensor 443. Oil Filter Adapter Bolt - Long 729. Engine Oil Pressure Sensor O-ring.
Page 366 1D-26 Engine Mechanical: Diagnostic Information and Procedures Diagnostic Starting Point - Engine Visual/Physical Inspection Mechanical • Inspect for aftermarket devices which could affect the Begin the system diagnosis by reviewing the operation of the Engine. Refer to “Checking “Disassembled Views”, “Engine Component Aftermarket Accessories: ”.
Page 367 Engine Mechanical: 1D-27 Base Engine Misfire without Internal Engine Noises Cause Correction Abnormalities, severe cracking, bumps, or missing areas, Replace the drive belt. Refer to “Drive Belt Replacement”. in the accessory drive belt Abnormalities in the accessory drive system and/or components may cause engine RPM variations and lead to a misfire DTC.
Page 368 1D-28 Engine Mechanical: Cause Correction Worn Piston Rings • Inspect the spark plugs for oil deposits. Refer to “Spark Oil consumption may or may not cause the engine to Plug Inspection: ” for the 3.6L engine. misfire. • Inspect the cylinders for a loss of compression. Refer to “Engine Compression Test”.
Page 369 Engine Mechanical: 1D-29 Base Engine Misfire with Abnormal Valve Train Noise Cause Correction Worn or loose followers, valve rocker arms Replace the followers, valve rocker arms, as required. The follower, valve rocker arm, roller bearing should be intact and in the proper position. Stuck valves Repair or replace as required.
Page 370 1D-30 Engine Mechanical: Upper Engine Noise, Regardless of Engine Speed Cause Correction Low oil pressure 1. Perform an oil pressure test. Refer to “Oil Pressure Diagnosis and Testing: ”. 2. Repair or replace as required. Loose and/or worn follower, valve rocker arm 1.
Page 371 Engine Mechanical: 1D-31 Cause Correction Oil pump screen loose, damaged or restricted 1. Inspect the oil pump screen. 2. Repair or replace as required. Excessive piston-to-cylinder bore clearance 1. Inspect the piston and cylinder bore. 2. Repair as required. Excessive piston pin-to-bore clearance 1.
Page 372 1D-32 Engine Mechanical: Engine Will Not Crank - Crankshaft Will Not Rotate Cause Correction Seized accessory drive system component 1. Remove the accessory drive belt or belts. 2. Rotate the crankshaft by hand at the crankshaft balancer or the engine flywheel location. 3.
Page 373 Engine Mechanical: 1D-33 Cause Correction Seized or broken valve train components 1. Inspect the followers, rocker arms. 2. Inspect the lifters. 3. Inspect the valves. 4. Inspect the valve springs. 5. Repair as required. Coolant in Combustion Chamber Cause Correction DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust pipe may indicate coolant in the combustion chamber.
Page 374 1D-34 Engine Mechanical: Engine Compression Test – When low compression is caused by the valves, the measurement is low on the first stroke and Special tool does not build up even with the addition of oil. J 39313 Spark Plug Port Adapter –...
Page 375 Engine Mechanical: 1D-35 6. Apply shop air pressure to the J 35667-A and adjust Results of Incorrect Operation according to the manufacturers instructions. A plugged crankcase ventilation housing or hose may contribute to the following conditions: 7. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive •...
Page 376 1D-36 Engine Mechanical: Misalignment of the pulleys may be caused from This test is to verify that the drive belt is not too long, improper mounting of the accessory drive component, which would prevent the drive belt tensioner from incorrect installation of the accessory drive component working properly.
Page 377 Engine Mechanical: 1D-37 Step Action Clean the drive belt pulleys with a suitable wire brush. Go to Step 20 Go to Step 6 Did you complete the repair? Inspect for misalignment of the pulleys. Go to Step 7 Go to Step 8 Are any of the pulleys misaligned? Replace or repair any misaligned pulleys.
Page 378 1D-38 Engine Mechanical: Drive Belt Rumbling and Vibration This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be Diagnosis confused with an internal engine noise due to the Diagnostic Aids similarity in the description.
Page 379 Engine Mechanical: 1D-39 Step Action 1. Remove the drive belt. If the engine has multiple drive belts, remove the belts one Go to “Symptoms - at a time and perform the test below each time a belt is Engine Mechanical” removed.
Page 380 1D-40 Engine Mechanical: Drive Belt Falls Off and Excessive Wear straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that Diagnosis accessory drive component for the proper installation Diagnostic Aids procedure of that pulley.
Page 381 Engine Mechanical: 1D-41 Step Action Inspect for improper, loose or missing fasteners. Go to Step 8 Go to Step 9 Did you find loose or missing fasteners? CAUTION Refer to “Fastener Notice: ”. 1. Tighten any loose fasteners. Refer to “Fastener Tightening Go to Step 9 System OK Specifications - Engine Mechanical - 3.6L (LY7): ”.
Page 382 1D-42 Engine Mechanical: Vibration Analysis - Engine Test Description The numbers below refer to the step numbers on the diagnostic table. If powertrain related DTCs are present, there may be a powertrain performance condition present which could be a contributing cause to the customer's concern. Making comparisons of the customer's vehicle with an equally equipped, same model year and type, KNOWN GOOD vehicle will help determine if certain disturbances may be characteristic of a vehicle design.
Page 383 Engine Mechanical: 1D-43 Step Action Compare the test results of the customer's vehicle to the results of the same tests run, at the same engine RPM, on an equally-equipped, same model year and type, KNOWN GOOD vehicle. Refer to “Vehicle-to-Vehicle Diagnostic Comparison: ”Vehicle-to-Vehicle Diagnostic Comparison.
Page 384 1D-44 Engine Mechanical: Vibration Analysis - Engine/Accessory Non-rotating engine driven accessory component systems can no longer produce a unique disturbance. Isolation Test Description Non-rotating engine driven accessory components can The numbers below refer to the step numbers on the no longer produce a unique disturbance. If a disturbance diagnostic table.
Page 385 Engine Mechanical: 1D-45 Step Action Inspect the powertrain mounts—engine, transmission, transfer case, and direct-mount drive axle, if equipped—and any powertrain braces for the following conditions: • Loose and/or missing fasteners • Improper alignment Go to Step 13 Go to Step 6 •...
Page 386 1D-46 Engine Mechanical: Step Action CAUTION Do not run the engine for longer than 60 seconds with the accessory drive belt, or belts removed, or overheating and/or damage may result. 1. Remove the engine accessory drive belt, or belts. 2. Block the front wheels. 3.
Page 387 Engine Mechanical: 1D-47 Step Action 1. Mark the face of the suspected accessory pulleys, including any related idler pulleys, near the outer edge with a paint mark. 2. Install the J 38792-25, Inductive Pickup Timing Light to the J 38792-A. For information on the use of the EVA features, refer to “Electronic Vibration Analyzer (EVA) Description and Operation: ”.
Page 388 1D-48 Engine Mechanical: Step Action Inspect the components of the engine driven accessory system for the following: • Loose and/or missing fasteners – Heat Shields, if equipped – Joints and/or couplings: Nuts, bolts, studs, clamps, straps – Bracket and/or insulator mounting •...
Page 389 Engine Mechanical: 1D-49 Step Action Check the vehicle to determine if the disturbance is now significantly reduced or eliminated. Perform the following steps: 1. Install a scan tool into the customer's vehicle. 2. Install the J 38792-A, if available, into the customer's vehicle;...
Page 390 1D-50 Engine Mechanical: Vibration Analysis - Engine Balance An engine flywheel that has excessive lateral runout, when combined with the extra mass of the clutch Test Description pressure plate and clutch driven plate, can produce a The numbers below refer to the step numbers on the disturbance.
Page 391 Engine Mechanical: 1D-51 Step Action 1. With the flywheel/flexplate-to-torque converter access cover still removed, and with the vehicle still raised, mark the position of the transmission torque converter in relation to the engine flywheel/flexplate. 2. Disconnect the torque converter and move it away from the flywheel/flexplate.
Page 392 1D-52 Engine Mechanical: Step Action 1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”. 2. Re-index the transmission torque converter to the engine flywheel/flexplate, 120 degrees from its original position. 3. Reconnect the transmission torque converter to the engine flywheel/flexplate.
Page 393 Engine Mechanical: 1D-53 Step Action 1. Remove the clutch pressure plate and clutch driven plate from the engine flywheel. 2. Inspect the engine flywheel for the following: – Looseness at the engine crankshaft – Cracks, warpage and/or damage – Missing balance weights 3.
Page 394 1D-54 Engine Mechanical: Step Action Check the vehicle to determine if the disturbance is now significantly reduced or eliminated. Perform the following steps: 1. Install or connect any components that were removed or disconnected during diagnosis. 2. Install a scan tool into the customer's vehicle. 3.
Page 395 Engine Mechanical: 1D-55 Engine Order Classification Engine First Order Classification 1. Convert the engine speed in revolutions per minute (RPM), recorded during duplication of the disturbance into Hertz, revolutions per second (RPS), by dividing the RPM by 60 seconds. Refer to the following example: 1,200 RPM divided by 60 = 20 Hz (or RPS) 2.
Page 396 1D-56 Engine Mechanical: Engine Driven Accessories Related to Engine Order Engine driven accessory systems can be related to specific engine orders depending upon the relationship of the accessory pulley diameter to the crankshaft pulley diameter. For example: • If the crankshaft pulley measured 20 cm (8 in) in diameter and one of the engine driven accessory pulleys measured 10 cm (4 in) in diameter, then that accessory pulley would rotate 2 times for every one rotation of the crankshaft pulley.
Page 397 Engine Mechanical: 1D-57 Engine Arrangement 90 Degree V6 Engine W/O Balance With Balance 60 Degree V6 With Balance 90 Degree V8 Order Shaft Shaft Shaft Characteristic - ENGINE FIRING FREQUENCY Possible Possible - Possible Possible Possible Possible Possible 2 ½ Order Engine Driven Engine Driven Powertrain...
Page 398 1D-58 Engine Mechanical: Repair Instructions Air Cleaner Outlet Duct Replacement Installation Procedure Removal Procedure 1. Install the air cleaner intake duct to the MAF/IAT sensor and the throttle body. 1. Remove the fuel injector sight shield. Refer to “Fuel Injector Sight Shield Replacement”. CAUTION 2.
Page 399 Engine Mechanical: 1D-59 Air Cleaner Element Replacement Installation Procedure Removal Procedure 1. Install the air cleaner element. 2. Rotate and close the air cleaner upper half. 1. Remove the air cleaner outlet duct. Refer to “Air Cleaner Outlet Duct Replacement”. 3.
Page 400 1D-60 Engine Mechanical: Air Cleaner Assembly Replacement Installation Procedure Removal Procedure 1. If the air cleaner assembly was replaced, install the MAF/IAT sensor. Refer to “Mass Airflow Sensor/ 1. Remove the air cleaner outlet duct. Refer to “Air Intake Air Temperature Sensor Replacement: ”. Cleaner Outlet Duct Replacement”.
Page 401 Engine Mechanical: 1D-61 Throttle Body Assembly Replacement Installation Procedure Removal Procedure 1. Position a NEW throttle body gasket to the upper intake manifold. 1. Remove the air cleaner outlet duct. Refer to “Air Cleaner Outlet Duct Replacement”. 2. Position the throttle body to the upper intake manifold.
Page 402 1D-62 Engine Mechanical: Throttle Body Service Drive Belt Replacement Removal Procedure NOTE 1. Remove the air cleaner assembly. Refer to “Air Over extended time and mileage, deposits Cleaner Assembly Replacement”. may accumulate on the back of the throttle 2. Install the engine support fixture. Refer to “Engine valve plate.
Page 403 Engine Mechanical: 1D-63 Installation Procedure Drive Belt Tensioner Replacement Removal Procedure 1. Install the drive belt to the crankshaft pulley, the tensioner and the generator. 1. Remove the drive belt. Refer to “Drive Belt 2. Rotate the drive belt tensioner clockwise. Replacement”.
Page 404 1D-64 Engine Mechanical: Drive Belt Idler Pulley Replacement Removal Procedure 7. Remove the drive belt idler pulley. Installation Procedure 1. Remove the drive belt. Refer to “Drive Belt Replacement”. 2. Completely loosen the idler pulley bolt. 3. Disconnect the negative battery cable. Refer to “Battery Negative Cable Disconnection and Connection: ”.
Page 405 Engine Mechanical: 1D-65 6. Connect the generator electrical connector (1). CAUTION 7. Install the drive belt. Refer to “Drive Belt Refer to “Fastener Notice: ”. Replacement”. 8. Connect the negative battery cable. Refer to “Battery 3. Tighten the generator and idler pulley bolt in Negative Cable Disconnection and Connection: ”.
Page 406 1D-66 Engine Mechanical: Engine Rear Mount Replacement 1. Position engine mount in place and install engine Removal Procedure mount bracket to engine mount bolt. Tightening torque Tighten the bolt to 50 N⋅m (38 lb ft). 2. Install the engine mount to frame bolts (1). Tightening torque Tighten the engine mount bolts to 50 N⋅m (38 lb ft).
Page 407 Engine Mechanical: 1D-67 Installation Procedure 7. Remove the upper engine mount bracket nuts (1). 8. Remove the lower bracket bolts (2). CAUTION 9. Remove the ABS connector clip from the frame. Refer to “Fastener Notice: ” in Cautions and 10. Remove the mount (3) and the lower bracket (4) Notices.
Page 408 1D-68 Engine Mechanical: 8. Lower the vehicle. 9. Remove the engine support. Refer to “Engine Support Fixture”. 10. Install the drive belt. Refer to “Drive Belt Replacement”. 11. Install the air cleaner assembly. Refer to “Air Cleaner Assembly Replacement”. Engine Mount Bracket Replacement - Right Side Removal Procedure 4.
Page 409 Engine Mechanical: 1D-69 6. Remove the ABS connector clip from the frame. 10. Remove the mount (3) and the lower bracket (4) from the vehicle. 7. Remove the upper engine mount bracket nuts (1). 11. Remove the upper bracket. 8. Remove the lower bracket bolts (2). Installation Procedure 9.
Page 410 1D-70 Engine Mechanical: Engine Mount Strut Replacement - Right Side Removal Procedure 4. Install the engine mount upper bracket and bolt (1) to the engine. Do not tighten the bolt. 1. Remove the air cleaner assembly. Refer to “Air Cleaner Assembly Replacement”. 2.
Page 411 Engine Mechanical: 1D-71 Installation Procedure 1. Position the strut (2) to the side rail, then install the strut to side rail nuts (3). Tightening torque Tighten the nuts to 110 N⋅m (81 lb ft). 2. Install the engine mount strut to bracket bolts (1). Tightening torque Tighten the bolts to 25 N⋅m (18 lb ft).
Page 412 1D-72 Engine Mechanical: Fuel Injector Sight Shield Replacement Crankcase Ventilation Hoses/Pipes Replacement (Front) Removal Procedure Removal Procedure 1. Remove the oil fill cap. 1. Remove the engine cover. Refer to “Fuel Injector 2. Lift upward and remove cover from ballstuds. Sight Shield Replacement”.
Page 413 Engine Mechanical: 1D-73 Crankcase Ventilation Hoses/Pipes Upper Intake Manifold Replacement Replacement (Rear) Removal Procedure Removal Procedure 1. Remove the engine cover. Refer to “Fuel Injector Sight Shield Replacement”. 1. Remove the engine cover. Refer to “Fuel Injector Sight Shield Replacement”. 2.
Page 414 1D-74 Engine Mechanical: 8. Remove the bleed pipe hose clamp (2). 9. Reposition the bleed pipe. 10. Remove the brake booster vacuum hose from the intake manifold. 5. Disconnect the PCV line (2) from the top of the intake manifold and reposition aside. 11.
Page 415 Engine Mechanical: 1D-75 Installation Procedure 5. Install the engine harness retaining clips. 1. Install the upper intake manifold gaskets to the lower 6. Install the brake booster vacuum hose to the intake intake manifold and install the fir tree retainers to manifold.
Page 416 1D-76 Engine Mechanical: 12. Connect the EVAP canister purge line (3). 14. Connect the ETC electrical connector. 15. Install the air cleaner outlet duct. 13. Connect the PCV line (2) to the top of the intake manifold. 16. Install the fresh air PCV line (1) to the air cleaner inlet duct.
Page 417 Engine Mechanical: 1D-77 Lower Intake Manifold Replacement 3. Install the fuel injectors and fuel rail. Refer to “Fuel Injector and Fuel Rail Replacement: ”. Removal Procedure Tightening torque Tighten the bolts to 23 N⋅m (17 lb ft). Crankshaft Balancer Replacement Special tool EN 46106 Flywheel Holding Tool J 38416-2 Crankshaft Button...
Page 418 1D-78 Engine Mechanical: Installation Procedure 6. Using engine support fixture, lower engine approximately two inches. 1. The EN 46106 must be installed onto the flywheel. 7. Remove the crankshaft balancer bolt. 2. Use the J 41998-B, nut, bearing and washer to install the crankshaft balancer.
Page 419 Engine Mechanical: 1D-79 4. Place the crankshaft balancer in position on the 10. Remove the EN 46106. crankshaft. 11. Install the starter. Refer to “Starter Installation: 5. Thread the J 41998-B in the crankshaft. Ensure you ”Starter Installation. engage at least 10 threads of the J 41998-B before 12.
Page 420 1D-80 Engine Mechanical: Installation Procedure 4. Clean the mating surfaces of the cylinder head and the camshaft cover. Refer to “Camshaft Cover Cleaning and Inspection”. NOTE Do not lubricate the crankshaft front oil seal 5. Install the EN 46101 onto the spark plug tubes of the or the crankshaft balancer sealing surfaces.
Page 421 Engine Mechanical: 1D-81 2. Place a bead 8 mm (0.3150 in) in diameter by 4 mm 4. Loosely install the left camshaft cover bolts. (0.1575 in) in height of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover split lines (1). CAUTION Refer to “Fastener Notice: ”.
Page 422 1D-82 Engine Mechanical: 6. Remove the EN 46101 from the spark plug tubes of 6. Install the EN 46101 onto the spark plug tubes of the the left cylinder head. left cylinder head. 7. Install NEW spark plugs into the left cylinder head. Installation Procedure Refer to“Spark Plug Replacement: ”.
Page 423 Engine Mechanical: 1D-83 2. Place a bead 8 mm (0.3150 in) in diameter by 4 mm 4. Loosely install the right camshaft cover bolts. (0.1575 in) in height of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover split lines (1). CAUTION Refer to “Fastener Notice: ”.
Page 424 1D-84 Engine Mechanical: 7. Remove the power steering pump and position aside. Refer to “Power Steering Pump Replacement: ”. 8. Remove the crankshaft balancer. Refer to “Crankshaft Balancer Replacement”. 9. Remove the camshaft position actuator valves from the front cover. Refer to “Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust: ”, “Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake: ”, “Camshaft Position Sensor...
Page 425 Engine Mechanical: 1D-85 13. Loosely install a 10 x 1.5 mm bolt in the “jackscrew” 16. Using the EN 46111, rotate the crankshaft until the hole (1). left cylinder head camshafts align with the EN 46105-2 and the right cylinder head camshafts align 14.
Page 426 1D-86 Engine Mechanical: 18. Install the EN 46105-2 to the left camshafts. 2. Install the engine front cover to cylinder block seal. Installation Procedure 3. Place a 3 mm (0.118 in) bead of RTV sealant, GM P/ N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover as shown (1).
Page 427 Engine Mechanical: 1D-87 CAUTION Refer to “Fastener Notice: ”. 7. Tighten the engine front cover bolts in the sequence shown. Tightening torque Tighten the engine front cover bolts in sequence to 23 N⋅m (17 lb ft). 8. Install the engine oil pan. Refer to “Oil Pan Replacement: ”.
Page 428 1D-88 Engine Mechanical: Secondary Camshaft Drive Chain 9. Remove the left bank secondary camshaft drive chain. Refer to“Secondary Camshaft Drive Chain Replacement - Left Side Removal - Left Side (Third Design)” “Secondary Removal Procedure Camshaft Drive Chain Removal - Left Side (Fourth 1.
Page 429 Engine Mechanical: 1D-89 6. Install the primary camshaft drive chain. Refer to 6. Remove the right bank secondary camshaft drive “Primary Camshaft Drive Chain Installation (Third chain. Refer to “Secondary Camshaft Drive Chain Design)” “Primary Camshaft Drive Chain Installation Removal - Right Side (Third Design)” “Secondary (Fourth Design)”.
Page 430 1D-90 Engine Mechanical: Secondary Camshaft Drive Chain Tensioner 3. Install the engine front cover. Refer to “Engine Front Cover Replacement”. Replacement - Left Side Removal Procedure Secondary Camshaft Drive Chain Tensioner 1. Remove the spark plugs in order to ease crankshaft/ Replacement - Right Side engine rotation.
Page 431 Engine Mechanical: 1D-91 Installation Procedure 5. Remove the left secondary camshaft drive chain shoe bolt. 1. Install the right bank secondary camshaft drive chain tensioner. Refer to “Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design)”“Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Fourth Design)”.
Page 432 1D-92 Engine Mechanical: Installation Procedure CAUTION Refer to “Fastener Notice: ”. 3. Install the secondary camshaft drive chain shoe bolt. Tightening torque Tighten the secondary camshaft drive chain shoe bolt to 23 N⋅m (17 lb ft). 4. Install the left bank secondary camshaft drive chain tensioner.
Page 433 Engine Mechanical: 1D-93 Installation Procedure 4. Remove the left bank secondary camshaft drive chain guide. Refer to “Secondary Camshaft Drive 1. Install the right bank secondary camshaft drive chain Chain Guide Removal - Left Side (Third Design)” shoe. Refer to “Secondary Camshaft Drive Chain “Secondary Camshaft Drive Chain Guide Removal - Shoe Installation - Right Side (Third Design)”...
Page 434 1D-94 Engine Mechanical: Secondary Camshaft Drive Chain Guide Installation Procedure Replacement - Right Side Removal Procedure 1. Remove the spark plugs in order to ease crankshaft/ engine rotation. Refer to “Spark Plug Replacement: ”. 2. Remove the engine front cover. Refer to “Engine Front Cover Replacement”.
Page 435 Engine Mechanical: 1D-95 Primary Camshaft Drive Chain and Sprockets Replacement Special tool EN 46111 Crankshaft Rotation Socket Removal Procedure 1. Remove the spark plugs in order to ease crankshaft/ engine rotation. Refer to “Spark Plug Replacement: ”. 2. Remove the engine front cover. Refer to “Engine Front Cover Replacement”.
Page 436 1D-96 Engine Mechanical: Installation Procedure 5. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) 1. Ensure the crankshaft sprocket is installed with the aligned to the stage one timing mark on the oil pump timing mark (1) visible.
Page 437 Engine Mechanical: 1D-97 9. Install the right bank secondary camshaft drive 4. Remove the right bank secondary camshaft drive chain. Refer to “Secondary Camshaft Drive Chain chain shoe. Refer to “Secondary Camshaft Drive Installation - Right Side (Third Design)” “Secondary Chain Shoe Removal - Right Side (Third Design)”...
Page 438 1D-98 Engine Mechanical: Installation Procedure 11. If you are servicing the left bank camshaft intermediate drive chain idler, perform the following 1. If you are servicing the left bank idler sprocket, steps: perform the following steps: a. Remove the left bank secondary camshaft drive a.
Page 439 Engine Mechanical: 1D-99 9. Install the right bank secondary camshaft drive chain tensioner. Refer to “Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design)” “Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Fourth Design)”. 10. Install the spark plugs. Refer to “Spark Plug Replacement: ”.
Page 440 1D-100 Engine Mechanical: Installation Procedure 1. Remove the spark plugs in order to ease crankshaft/ engine rotation. Refer to “Spark Plug Replacement: ”. 2. Remove the engine front cover. Refer to “Engine Front Cover Replacement”. 3. Remove the primary camshaft drive chain tensioner. Refer to “Primary Camshaft Drive Chain Tensionser Removal (Third Design)”...
Page 441 Engine Mechanical: 1D-101 Camshaft Position Actuator Replacement - Bank 2 (Left Side) Exhaust Special tool EN-48313 Timing Chain Retention Tool Removal Procedure NOTE Ensure that the camshaft timing chain and the camshaft position actuators are marked for proper assembly. 6. Use a paint stick to create an alignment mark on one of the timing chain links (2) and the adjacent tooth on 1.
Page 442 1D-102 Engine Mechanical: 10. Insert the EN-48313 between the camshaft NOTE actuators, rearward of the timing chain until the Ensure that the foot (1) of the EN-48313 is bottom line that is scribed in the body of the tool (2) engaged into one of the link pockets to is adjacent to the top surface of the cylinder head prevent tool slippage during tightening of the...
Page 443 Engine Mechanical: 1D-103 18. Use an open end wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt. 19. Remove the left exhaust camshaft position actuator bolt. 20. Remove the left exhaust camshaft position actuator. When removing the actuator, place the chain on the engine block side of the actuators.
Page 444 1D-104 Engine Mechanical: Camshaft Position Actuator Replacement - 2. Install the camshaft. Refer to “Camshaft Replacement - Right Side”. Bank 1 (Right Side) Exhaust Removal Procedure Camshaft Position Actuator Replacement - CAUTION Bank 2 (Left Side) Intake Removal Procedure Refer to “Torque Reaction Against Timing Drive Chain Notice”.
Page 445 Engine Mechanical: 1D-105 NOTE Installation Procedure Use an open-end wrench at the camshaft hex to prevent camshaft/engine rotation. 2. Tighten the camshaft position actuator bolt. Refer to “Camshaft Position Actuator Installation - Left Side Intake (Third Design)” “Camshaft Position Actuator Installation - Left Side Intake (Fourth Design)”.
Page 446 1D-106 Engine Mechanical: Camshaft Replacement - Left Side Special tool EN 46108 Timing Chain Retention Tool EN 46111 Crankshaft Rotation Socket Removal Procedure 1. Remove the lower intake manifold. Refer to “Lower Intake Manifold Replacement”. 2. Remove the left bank camshaft cover. Refer to “Camshaft Cover Replacement - Left Side”.
Page 447 Engine Mechanical: 1D-107 1. Locate the camshafts to the cylinder head and assemble the camshaft actuators to the camshafts. 2. Install the camshafts and the camshaft bearing caps. Refer to“Camshaft Installation - Left Side”. 3. Remove the EN 46108. NOTE Ensure that the camshaft timing chain and the camshaft position actuators are marked for proper assembly.
Page 448 1D-108 Engine Mechanical: Camshaft Replacement - Right Side Special tool EN 46108 Timing Chain Retention Tool EN 46111 Crankshaft Rotation Socket Removal Procedure 1. Remove the lower intake manifold. Refer to “Lower Intake Manifold Replacement”. 2. Remove the camshaft cover. Refer to “Camshaft Cover Replacement - Right Side”.
Page 449 Engine Mechanical: 1D-109 1. Locate the camshafts to the cylinder head and assemble the camshaft actuators to the camshafts. 2. Install the camshafts and the camshaft bearing caps. Refer to“Camshaft Installation - Right Side”. 3. Remove the EN 46108. 4. Install the crankshaft balancer. Refer to “Crankshaft Balancer Installation”.
Page 450 1D-110 Engine Mechanical: Valve Rocker Arm Replacement - Left Side Valve Rocker Arm Replacement - Right Side Removal Procedure Removal Procedure 1. Remove the applicable camshaft(s). Refer to 1. Remove the applicable camshaft(s). Refer to “Camshaft Replacement - Left Side”. “Camshaft Replacement - Left Side”.
Page 451 Engine Mechanical: 1D-111 Valve Lifter Replacement - Left Side Valve Lifter Replacement - Right Side Removal Procedure Removal Procedure 1. Remove the applicable camshaft(s). Refer to 1. Remove the applicable camshaft(s). Refer to “Camshaft Replacement - Left Side”. “Camshaft Replacement - Right Side”. 2.
Page 452 1D-112 Engine Mechanical: Valve Stem Oil Seal and Valve Spring Replacement - Left Side Special tool EN 46106 Flywheel Holding Tool EN 46110 On-Vehicle Valve Spring Compressor EN 46116 Valve Stem Seal Remover/Installer J 39313 Spark Plug Port Adapter Removal Procedure 1.
Page 453 Engine Mechanical: 1D-113 Installation Procedure 12. Remove the valve spring. 1. Use the EN 46116 (1) in order to install the valve stem seal (2). 13. Use the EN 46116 (1) in order to remove the valve stem seal (2). 2.
Page 454 1D-114 Engine Mechanical: Valve Stem Oil Seal and Valve Spring Replacement - Right Side Special tool EN 46106 Flywheel Holding Tool EN 46110 On-Vehicle Valve Spring Compressor EN 46116 Valve Stem Seal Remover/Installer J 39313 Spark Plug Port Adapter Removal Procedure 1.
Page 455 Engine Mechanical: 1D-115 7. Install the EN 46110 above the applicable cylinder as 12. Remove the valve springs. shown. 8. Tighten the EN 46110 valve spring compressor nut (2). 13. Use the EN 46116 (1) in order to remove the valve stem seal (2).
Page 456 1D-116 Engine Mechanical: Installation Procedure 4. Install the EN 46110 above the applicable valve spring as shown. 1. Use the EN 46116 (1) in order to install the valve Tighten the EN 46110 valve spring compressor nut stem seals (2). (2).
Page 457 Engine Mechanical: 1D-117 Cylinder Head Replacement - Left Side Removal Procedure 1. Remove the left bank secondary timing chain. Refer to “Secondary Camshaft Drive Chain Replacement - Left Side”. 2. Remove the oil level indicator. Refer to “Oil Level Indicator and Tube Replacement: ”. 3.
Page 458 1D-118 Engine Mechanical: Installation Procedure 1. If necessary, perform the following steps: – Assemble the cylinder head. Refer to “Cylinder Head Assemble”. – Install the camshaft. Refer to “Camshaft Installation - Left Side”. – Install the exhaust manifold to the cylinder head. Refer to “Exhaust Manifold Installation - Left Side: ”.
Page 459 Engine Mechanical: 1D-119 Installation Procedure 1. If necessary, perform the following steps: – Assemble the cylinder head. Refer to “Cylinder Head Assemble”. – Install the camshaft. Refer to “Camshaft Installation - Right Side”. – Install the exhaust manifold to the cylinder head. Refer to “Exhaust Manifold Installation - Right Side: ”.
Page 460 1D-120 Engine Mechanical: Engine Flywheel Replacement Crankshaft Rear Oil Seal and Housing Replacement Removal Procedure Removal Procedure 1. Remove the engine flywheel. Refer to “Engine Flywheel Replacement”. 2. Remove the oil pan. Refer to “Oil Pan Replacement: ”. 1. Remove the transmission. Refer to “Transaxle Replacement: ”.
Page 461 Engine Mechanical: 1D-121 Engine Replacement Removal Procedure 1. Remove the battery box and carefully set the engine control module (ECM) on top of the engine. Refer to “Battery Box Replacement: ”. 2. Disconnect the ECM connector from the under-hood fuse block. 3.
Page 462 1D-122 Engine Mechanical: 27. Remove the right and left outer tie rod ends from the 29. Remove the right and left lower ball joints from the steering knuckles. Refer to “Rack and Pinion Outer steering knuckles. Refer to “Lower Control Arm Tie Rod End Replacement: ”.
Page 463 Engine Mechanical: 1D-123 NOTE Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain. 41. Carefully raise the vehicle body up away from the powertrain. 33. Lower the vehicle. 34.
Page 464 1D-124 Engine Mechanical: 44. Disconnect the engine electrical wiring harness from 46. If equipped with an engine coolant heater, the following components: disconnect the coolant heater cord. – Generator (1) 47. Remove the throttle body assembly. Refer to “Throttle Body Assembly Replacement”. –...
Page 465 Engine Mechanical: 1D-125 Installation Procedure 1. Remove the engine from the engine stand. 50. Remove the torque converter bolts. 51. Install the engine support adapters to the engine. Refer to “Engine Support Fixture”. 2. Align the engine to the frame and automatic transaxle.
Page 466 1D-126 Engine Mechanical: 8. Install the starter motor. Refer to “Starter Motor Replacement: ”. 12. Connect the engine electrical wiring harness to the following components: 9. Install the engine to transaxle brace (3) and bolts (1, – Transmission module (4) –...
Page 467 Engine Mechanical: 1D-127 14. Connect the left and right cylinder head engine 17. Install NEW frame-to-body bolts. electrical wiring harness to the following Tightening torque components: Tighten the bolts to 155 N⋅m (114 lb ft). – Camshaft position actuators (2) 18.
Page 468 1D-128 Engine Mechanical: 23. Remove the block of wood (1) between the frame 27. Install the right and left stabilizer shaft links to the and the engine oil pan used to support the engine stabilizer shaft. Refer to “Stabilizer Shaft Link while the bolts were removed from the right engine Replacement: ”.
Page 469 Engine Mechanical: 1D-129 37. Install the radiator inlet hose. Refer to “Radiator Inlet Hose Replacement: ”. 38. Connect the heater hoses to the engine. Refer to “Heater Outlet Hose Replacement: ”. 39. Untie the radiator, AC condenser, and fan module assembly from the upper radiator support.
Page 470 1D-130 Engine Mechanical: Drive Belt Tensioner Removal 45. Connect the brake booster vacuum hose (2) to the intake manifold. 1. Remove the drive belt tensioner bracket bolts. 46. Position the clamp (1) on the brake booster vacuum 2. Remove the drive belt tensioner assembly. hose connection.
Page 471 Engine Mechanical: 1D-131 Engine Flywheel Removal Reference: “Crankshaft Balancer Removal: ”. Special tool EN 46106 Flywheel Holding Tool 2. Remove the crankshaft balancer bolt. 1. Remove the engine flywheel bolts and discard. 3. Install the J 38416-2 in the nose of the crankshaft. 4.
Page 472 1D-132 Engine Mechanical: 3. Remove the EN 46106. 2. Remove the engine coolant air bleed pipe bracket Reference: “Engine Flywheel Cleaning and Inspection: ”. bolts from the upper intake manifold. Intake Manifold Removal Reference: “Engine Flywheel Removal: ”. 3. Remove the fuel injector harness connector from the engine coolant air bleed pipe bracket.
Page 473 Engine Mechanical: 1D-133 4. Remove the engine coolant air bleed pipe. 6. Disconnect and remove the intake manifold-to- solenoid evaporative emissions (EVAP) hose from the intake manifold and from the EVAP solenoid. 5. Disconnect and remove the dirty air PCV hose from the intake manifold and the right camshaft cover fitting.
Page 474 1D-134 Engine Mechanical: 8. Remove the EVAP solenoid. 11. Remove the intake manifold assembly. 9. Remove the long intake manifold bolts. 12. Remove and discard the lower intake manifold gasket. Reference: “Intake Manifold Disassemble: ”. 10. Remove the short intake manifold bolts.
Page 475 Engine Mechanical: 1D-135 Camshaft Cover Removal - Left Side 3. Remove the spark plugs. Reference: “Intake Manifold Removal: ”. 4. Remove the left camshaft cover bolts. 1. Remove the ignition coil bolts. 5. Remove the left camshaft cover from the left cylinder head.
Page 476 1D-136 Engine Mechanical: Camshaft Cover Removal - Right Side 3. Remove the spark plugs. Reference: “Camshaft Cover Removal - Left Side: ”. 4. Remove the right camshaft cover bolts. 1. Remove the ignition coil bolts. 5. Remove the right camshaft cover from the right cylinder head.
Page 477 Engine Mechanical: 1D-137 Engine Front Cover Removal (Third Design) Reference: “Water Pump Removal: ”. Special tool EN 46105 Camshaft Locking Tool EN 46111 Crankshaft Rotation Socket 5. Remove the engine front cover bolts that hold the engine front cover deadener into position. 1.
Page 478 1D-138 Engine Mechanical: 11. Using the EN 46111, rotate the crankshaft until the CAUTION left cylinder head camshafts align with the EN Do not pry between the engine front cover 46105-2 and the right cylinder head camshafts align and the camshaft position sensors or the with the EN 46105-1.
Page 479 Engine Mechanical: 1D-139 13. Install the EN 46105-2 to the left camshafts. 3. Remove the camshaft position actuator valve bolts. Reference: “Engine Front Cover Disassemble: ”. 4. Remove the camshaft position actuator valves from the front cover. Engine Front Cover Removal (Fourth Design) Reference: “Water Pump Removal: ”.
Page 480 1D-140 Engine Mechanical: CAUTION Do not pry between the engine front cover and the camshaft position sensors or the camshaft position actuators in order to shear the RTV. Use the pry points and a bolt in the jackscrew hole in order to remove the engine front cover.
Page 481 Engine Mechanical: 1D-141 11. Using the EN 46111, rotate the crankshaft until the Secondary Camshaft Drive Chain Tensioner left cylinder head camshafts align with the EN Removal - Right Side (Third Design) 46105-2 and the right cylinder head camshafts align Reference: “Engine Front Cover Removal (Third with the EN 46105-1.
Page 482 1D-142 Engine Mechanical: Secondary Camshaft Drive Chain Tensioner Secondary Camshaft Drive Chain Shoe Removal - Right Side (Fourth Design) Removal - Right Side (Third Design) Reference: “Engine Front Cover Removal (Fourth Reference: “Secondary Camshaft Drive Chain Tensioner Design): ”. Removal - Right Side (Third Design): ”. 1.
Page 483 Engine Mechanical: 1D-143 Secondary Camshaft Drive Chain Shoe Secondary Camshaft Drive Chain Guide Removal - Right Side (Fourth Design) Removal - Right Side (Third Design) Reference: “Secondary Camshaft Drive Chain Tensioner Reference: “Secondary Camshaft Drive Chain Shoe Removal - Right Side (Fourth Design): ”. Removal - Right Side (Third Design): ”.
Page 484 1D-144 Engine Mechanical: Secondary Camshaft Drive Chain Removal - Primary Camshaft Drive Chain Tensionser Right Side (Third Design) Removal (Third Design) Reference: “Secondary Camshaft Drive Chain Guide Reference: “Secondary Camshaft Drive Chain Removal Removal - Right Side (Third Design): ”. - Right Side (Third Design): ”.
Page 485 Engine Mechanical: 1D-145 Primary Camshaft Drive Chain Tensionser Primary Camshaft Drive Chain Guide Removal (Fourth Design) Removal - Upper (Third Design) Reference: “Secondary Camshaft Drive Chain Removal Reference: “Primary Camshaft Drive Chain Tensionser - Right Side (Fourth Design): ”. Removal (Third Design): ”. 1.
Page 486 1D-146 Engine Mechanical: Primary Camshaft Drive Chain Guide Primary Camshaft Drive Chain Removal Removal - Lower (Third Design) (Third Design) Reference: “Primary Camshaft Drive Chain Guide Reference: “Primary Camshaft Drive Chain Guide Removal - Upper (Third Design): ”. Removal - Lower (Third Design): ”. 1.
Page 487 Engine Mechanical: 1D-147 Camshaft Intermediate Drive Chain Idler Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Third Design) Removal - Left Side (Third Design) Reference: “Primary Camshaft Drive Chain Removal Reference: “Camshaft Intermediate Drive Chain Idler (Third Design): ”. Removal - Right Side (Third Design): ”.
Page 488 1D-148 Engine Mechanical: Secondary Camshaft Drive Chain Tensioner Secondary Camshaft Drive Chain Shoe Removal - Left Side (Fourth Design) Removal - Left Side (Third Design) Reference: “Camshaft Intermediate Drive Chain Idler Reference: “Secondary Camshaft Drive Chain Tensioner Removal - Right Side (Fourth Design): ”. Removal - Left Side (Third Design): ”.
Page 489 Engine Mechanical: 1D-149 Secondary Camshaft Drive Chain Shoe Secondary Camshaft Drive Chain Guide Removal - Left Side (Fourth Design) Removal - Left Side (Third Design) Reference: “Secondary Camshaft Drive Chain Tensioner Reference: “Secondary Camshaft Drive Chain Shoe Removal - Left Side (Fourth Design): ”. Removal - Left Side (Third Design): ”.
Page 490 1D-150 Engine Mechanical: Secondary Camshaft Drive Chain Removal - Camshaft Intermediate Drive Chain Idler Left Side (Third Design) Removal - Left Side (Third Design) Reference: “Secondary Camshaft Drive Chain Guide Reference: “Secondary Camshaft Drive Chain Removal Removal - Left Side (Third Design): ”. - Left Side (Third Design): ”.
Page 491 Engine Mechanical: 1D-151 Crankshaft Sprocket Removal (Third Camshaft Position Actuator Removal - Left Design) Side Exhaust (Third Design) Reference: “Camshaft Intermediate Drive Chain Idler Reference: “Crankshaft Sprocket Removal (Third Removal - Left Side (Third Design): ”. Design): ”. Remove the crankshaft sprocket from the nose of the CAUTION crankshaft.
Page 492 1D-152 Engine Mechanical: Camshaft Position Actuator Removal - Left CAUTION Side Exhaust (Fourth Design) Refer to “Torque Reaction Against Timing Reference: “Crankshaft Sprocket Removal (Fourth Drive Chain Notice”. Design): ”. 1. Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt.
Page 493 Engine Mechanical: 1D-153 Camshaft Position Actuator Removal - CAUTION Right Side Exhaust (Third Design) Refer to “Torque Reaction Against Timing Reference: “Camshaft Position Actuator Removal - Left Drive Chain Notice”. Side Intake (Third Design): ”. 1. Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt.
Page 494 1D-154 Engine Mechanical: Camshaft Position Actuator Removal - Camshaft Removal - Left Side Right Side Intake (Fourth Design) Reference: “Camshaft Position Actuator Removal - Left Side Intake (Third Design): ”. Reference: “Camshaft Position Actuator Removal - Right Reference: “Camshaft Position Actuator Removal - Left Side Exhaust (Fourth Design): ”.
Page 495 Engine Mechanical: 1D-155 Valve Rocker Arm Removal - Left Side Reference: “Camshaft Removal - Left Side: ”. 4. Remove the camshaft bearing cap bolts. 5. Remove the camshaft bearing caps. Remove the valve rocker arms, camshaft followers, from the left cylinder head. Reference: “Valve Rocker Arms Cleaning and Inspection: ”.
Page 496 1D-156 Engine Mechanical: Cylinder Head Removal - Left Side Camshaft Removal - Right Side Reference: “Valve Lifter Removal - Left Side: ”. Reference: “Camshaft Position Actuator Removal - Right Side Intake (Third Design): ”. Reference: “Camshaft Position Actuator Removal - Right Side Intake (Fourth Design): ”.
Page 497 Engine Mechanical: 1D-157 Valve Rocker Arm Removal - Right Side Reference: “Camshaft Removal - Right Side: ”. 4. Remove the camshaft bearing cap bolts. 5. Remove the camshaft bearing caps. Remove the valve rocker arms, camshaft followers, from the right cylinder head. Reference: “Valve Rocker Arms Cleaning and Inspection: ”.
Page 498 1D-158 Engine Mechanical: Cylinder Head Removal - Right Side Crankshaft Rear Oil Seal and Housing Removal Reference: “Valve Lifter Removal - Right Side: ”. Reference: “Oil Pump Removal: ”. 1. Remove the right cylinder head bolts. 1. Remove the crankshaft rear oil seal housing bolts. 2.
Page 499 Engine Mechanical: 1D-159 e. If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod. If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
Page 500 1D-160 Engine Mechanical: 6. Install the EN 46121 into the connecting rod bolt 8. Remove the EN 46121 from the connecting rod bolt holes. holes. 9. Remove the upper connecting rod bearing from the connecting rod. 7. Using the EN 46121, push the connecting rod and piston assembly through the top of the cylinder.
Page 501 Engine Mechanical: 1D-161 Crankshaft Removal 11. Reattach the connecting rod cap to the connecting rod to prevent damage to their mating surfaces. The 1. Remove the crankshaft bearing cap side bolts. cap and rod are a matched set and must be kept 2.
Page 502 1D-162 Engine Mechanical: Crankshaft Bearing Removal 1. Prepare a piece of cardboard or equivalent, numbered 1-4 for bearing identification. Main bearing journals are numbered from the front of the engine. 5. Using two hands, lift the crankshaft straight up from the engine block.
Page 503 Engine Mechanical: 1D-163 Engine Block Disassemble Reference: “Crankshaft and Bearings Removal: ”. 4. Remove the cylinder block-to-oil pan alignment dowels. 1. Remove oil jet bolts. 2. Remove oil jets. 5. Remove the M14 right side oil gallery threaded plug. 3. Remove the right front oil pan rail oil gallery expansion plug.
Page 504 1D-164 Engine Mechanical: 7. Remove the M14 rear oil gallery threaded plug. 10. Remove the coolant expansion plugs. 8. Remove the M14 left side coolant drain threaded 11. Remove the cylinder block-to-transmission plug. alignment dowels. 9. Remove the M20 left side oil gallery threaded plug. 12.
Page 505 Engine Mechanical: 1D-165 Visual Inspection 13. Remove the cylinder block-to-cylinder head alignment dowels. 1. Inspect the crankshaft bearings journals for damage Reference: “Engine Block Cleaning and Inspection: ”. or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing journals are damaged the cylinder block assembly must be Engine Block Cleaning and Inspection replaced.
Page 506 1D-166 Engine Mechanical: Measuring Cylinder Bore Diameter 3. Measure both the thrust and non-thrust cylinder diameter at 100 mm (3.976 in) below the deck surface. Record your measurements. 4. Calculate the difference between the 2 measurements. The result will indicate out-of-round at the lower end of the cylinder.
Page 507 Engine Mechanical: 1D-167 Crankshaft and Bearings Cleaning and – Inspect the crankshaft main journals (5) for damage. Inspection – Inspect the crankshaft connecting rod journals (6) Reference: “Crankshaft and Bearings Removal: ”. for damage. Cleaning Procedure – Inspect the crankshaft oil passages (7) for obstructions.
Page 508 1D-168 Engine Mechanical: 2. Inspect for excessive scoring or discoloration on 1. Using a suitable fixture, support the crankshaft. both front and back of the bearing halves. 3. Inspect the main bearings for dirt embedded into the bearing material. 2. Install the J 7872. 3.
Page 509 Engine Mechanical: 1D-169 4. Measure the crankshaft thrust wall width (1) for wear using an inside micrometer. Refer to “Engine Mechanical Specifications”. 5. Measure the crankshaft thrust wall surface (2) for runout using the J 7872. Refer to “Engine Mechanical Specifications”. 6.
Page 510 1D-170 Engine Mechanical: Crankshaft Balancer Cleaning and – Worn, chunking or deteriorated rubber between the hub and pulley (3) Inspection – Damaged drive belt ribs (4) Reference: “Crankshaft Balancer Removal: ”. – Damaged webs (5) Cleaning Procedure 2. Repair or replace the crankshaft balancer as necessary.
Page 511 Engine Mechanical: 1D-171 – Cracks at welded areas that retain the ring gear onto the engine flywheel (3) – Damaged or missing ring gear teeth (5) 2. Replace the engine flywheel as necessary. Reference: “Engine Flywheel Installation: ”. Piston and Connecting Rod Disassemble Reference: “Piston, Connecting Rod, and Bearing Removal: ”.
Page 512 1D-172 Engine Mechanical: Piston, Connecting Rod, and Bearings Piston Measurement Procedure Cleaning and Inspection Reference: “Piston and Connecting Rod Disassemble: ”. Cleaning Procedure NOTE DO NOT wire brush any part of the piston. 1. Clean the piston skirts and the pins with a cleaning solvent.
Page 513 Engine Mechanical: 1D-173 b. Measure the end gap of the piston ring with feeler gages. Refer to “Engine Mechanical Specifications”. c. If the clearance exceeds the provided specifications, the piston rings must be replaced. d. Repeat the procedure for all the piston rings. 3.
Page 514 1D-174 Engine Mechanical: 3. There is a locating dimple (1) on the compression 5. If the connecting rod bores contain minor scratches rings near the end for identification. Install the or abrasions, clean the bores in a circular direction compression rings with the dimple facing up. with a light emery paper.
Page 515 Engine Mechanical: 1D-175 5. If the clearance is excessive, replace the piston pin. Piston and Piston Pin Installation Procedure If a new pin does not resolve the clearance problem, replace the connecting rod. Connecting Rod Crankshaft Bearing End NOTE • The arrow located on top of the piston must point toward the front of the engine.
Page 516 1D-176 Engine Mechanical: NOTE New piston pin retainers must be used. Never reuse the piston pin retainers. 5. Install NEW piston pin retainers using the EN-46745. Align the EN-46745 to the notch (1) in the piston. 6. Ensure that the piston pin retainers are fully seated in their grooves.
Page 517 Engine Mechanical: 1D-177 Connecting Rod Bearing Installation Procedure Reference: “Piston, Connecting Rod, and Bearing Installation: ”. Cylinder Head Disassemble Reference: “Cylinder Head Removal - Left Side: ”. Reference: “Cylinder Head Removal - Right Side: ”. Special tool EN 46116 Valve Stem Seal Remover/Installer EN 46117 Valve Stem Key Remover/Installer EN 46119 Off-Vehicle Valve Spring Compressor Adapter...
Page 518 1D-178 Engine Mechanical: WARNING Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing...
Page 519 Engine Mechanical: 1D-179 NOTE Cylinder Head Cleaning and Inspection Reference: “Cylinder Head Disassemble: ”. NEVER reuse a valve stem oil seal. Special tool 8. Remove the valve stem oil seal using the EN 46116 EN 46122 Camshaft Position Actuator Check-Ball and discard.
Page 520 1D-180 Engine Mechanical: 2. If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head. 3. Inspect the cylinder head for the following: – Cracks, damage or pitting in the combustion chambers – Debris in the oil galleries — Continue to clean the galleries until all debris is removed.
Page 521 Engine Mechanical: 1D-181 Deck Flatness Inspection Valve Guide Measurement 1. Ensure the cylinder head decks are clean and free of 1. Measure the valve stem (1)-to-guide (2) clearance. gasket material. Excessive valve stem-to-guide clearance may cause an excessive oil consumption and may also cause a 2.
Page 522 1D-182 Engine Mechanical: Valve Spring Inspection and Measurement Valve and Seat Grinding Reference: “Cylinder Head Disassemble: ”. Reference: “Cylinder Head Disassemble: ”. Special tool Valve Cleaning Procedure J 22738-B Valve Spring Tester 1. Use soft bristle wire brush to clean any carbon build- up from the valve head.
Page 523 Engine Mechanical: 1D-183 Valve Measurement and Reconditioning NOTE Overview The seat contact area must be at least 0.5 mm (0.020 in) from the outer diameter (margin) of NOTE the valve. If the contact area is too close to the margins, the seat must be reconditioned •...
Page 524 1D-184 Engine Mechanical: Valve Margin Measurement Procedure Valve-to-Seat Concentricity Measurement Procedure NOTE • Checking the valve-to-seat concentricity determines whether the valve and seat are sealing properly. • You must measure the valve face and the valve seat to ensure proper valve sealing. 1.
Page 525 Engine Mechanical: 1D-185 Valve and Seat Reconditioning Procedure 6. Install the valve in the cylinder head. – If you are using refaced valves, lap the valves into the seats with a fine grinding compound. The refacing and reseating operations should leave the refinished surfaces smooth and true so that minimal lapping is required.
Page 526 1D-186 Engine Mechanical: 6. If the maximum height specification is exceeded, a 1. Install the cylinder head coolant threaded plugs. new valve should be installed and the valve stem Tightening torque height re-measured. Tighten the cylinder head coolant threaded plug CAUTION to 31 N⋅m (23 lb ft).
Page 527 Engine Mechanical: 1D-187 5. Push and twist the valve stem oil seal into position on the valve guide until the seal positively locks on the guide using the EN 46116. 6. Lubricate the valve stem and valve guide ID with clean engine oil GM P/N 12345501 (Canadian P/N 992704) or equivalent.
Page 528 1D-188 Engine Mechanical: Camshaft Cleaning and Inspection Reference: “Camshaft Removal - Left Side: ”. Reference: “Camshaft Removal - Right Side: ”. Special tool J 7872 Magnetic Base Dial Indicator Cleaning Procedure 1. Clean the camshaft in solvent. WARNING Refer to “Safety Glasses Caution: ”. 2.
Page 529 Engine Mechanical: 1D-189 Camshaft Measurement 3. Measure the camshaft runout using the J 7872. Refer to “Engine Mechanical Specifications”. 1. With the camshaft in a suitable fixture, measure the camshaft for wear. 4. Measure the camshaft thrust width for wear using a depth micrometer.
Page 530 1D-190 Engine Mechanical: 5. Measure the camshaft thrust wall surface for runout 8. Place the J 7872 with the indicator tip on the base using J 7872. Refer to “Engine Mechanical circle (1) of the camshaft lobe. Specifications”. a. Place the J 7872 at zero. 6.
Page 531 Engine Mechanical: 1D-191 Camshaft Timing Drive Components 1. Inspect the stationary hydraulic lash adjuster (SHLA) Cleaning and Inspection (Third Design) in the following areas: Reference: “Camshaft Position Actuator Removal - Right – A plugged oil passage (1) Side Intake (Third Design): ”. –...
Page 532 1D-192 Engine Mechanical: 2. Inspect the back of the exhaust camshaft position 4. Inspect the back of the intake camshaft position actuators for the following: actuators for the following: – Sprocket damage (1) – Sprocket damage (1) – Camshaft locating pin damage (2) –...
Page 533 Engine Mechanical: 1D-193 – Damage to the wiring harness connection and/or – Damage to the bearing hub-to-engine block terminals (6) sealing surface (2) 2. Replace a damaged camshaft position actuator oil 3. Replace a damaged left intermediate sprocket. control valve. Right Intermediate Sprocket with Primary Inverted Left Intermediate Sprocket with Primary Inverted Tooth (IT) Chain...
Page 534 1D-194 Engine Mechanical: 3. Replace a damaged right intermediate sprocket. Primary Timing Chain with Inverted Tooth (IT) Chain Crankshaft Sprocket with Primary Inverted Tooth (IT) Chain 1. Inspect the primary timing chain for the following: – Binding or worn links (1) 1.
Page 535 Engine Mechanical: 1D-195 Primary Timing Chain Lower Guide Right Secondary Timing Chain Guide 1. Inspect the primary timing chain lower guide for the 1. Inspect the right secondary timing chain guides for following: the following: – Worn guide surface (1) –...
Page 536 1D-196 Engine Mechanical: 2. Inspect the back of the left secondary timing chain 2. Inspect the back of the right secondary timing chain shoe for a damaged, worn, or missing left secondary shoe for a damaged, worn, or missing right timing chain tensioner contact pad (1).
Page 537 Engine Mechanical: 1D-197 Left Secondary Timing Chain Tensioner 2. Inspect the right secondary timing chain tensioner for locked or binding timing chain tensioner. Reset the plunger (3) and ensure the plunger moves freely (2) in and out of the body of the tensioner. Refer to “Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design)”...
Page 538 1D-198 Engine Mechanical: Visual Inspection Camshaft Position Actuators 3. Inspect the front of the left intake camshaft position actuators for the following: – Sprocket damage (1) 1. Inspect the front of the exhaust camshaft position actuators for the following: – Reluctor/sensor wheel damage (2) –...
Page 539 Engine Mechanical: 1D-199 Camshaft Position Actuator Oil Control Valves 5. Inspect the front of the right intake camshaft position actuators for the following: 1. Inspect the camshaft position actuator oil control valves for the following: – Sprocket damage (1) – Blockage to the oil passage (1) –...
Page 540 1D-200 Engine Mechanical: – Damage to the hub bearing (2)—Ensure the hub – Damage to the hub bearing (2)—Ensure the hub bearing spins freely. If the hub bearing wobbles, is bearing spins freely. If the hub bearing wobbles, is noisy, or feels rough when rotated, replace the noisy, or feels rough when rotated, replace the intermediate sprocket.
Page 541 Engine Mechanical: 1D-201 Secondary Timing Chains with Inverted Tooth (IT) Primary Timing Chain Upper Guide Chain 1. Inspect the primary timing chain upper guide for the 1. Inspect the secondary timing chain for the following: following: – Binding or worn links (1) –...
Page 542 1D-202 Engine Mechanical: Left Secondary Timing Chain Guide Left Secondary Timing Chain Shoe 1. Inspect the left secondary timing chain guides for the 1. Inspect the front of the left secondary timing chain following: shoe for the following: – Worn guide surface (1) –...
Page 543 Engine Mechanical: 1D-203 Right Secondary Timing Chain Shoe Primary Timing Chain Tensioner 1. Inspect the front of the right secondary timing chain 1. Inspect the primary timing chain tensioner for worn shoe for the following: primary timing chain tensioner shoe surface (1). –...
Page 544 1D-204 Engine Mechanical: 3. Replace a damaged left secondary timing chain Engine Front Cover Disassemble tensioner. Reference: “Engine Front Cover Removal (Third Design): ”. Right Secondary Timing Chain Tensioner Reference: “Engine Front Cover Removal (Fourth Design): ”. Special tool J 45000 Seal Remover 1.
Page 545 Engine Mechanical: 1D-205 4. Dry the engine front cover with compressed air. Inspection Procedure 3. Remove the water pump seal from the engine front cover. 4. Discard the water pump seal. 1. Inspect the exterior of the engine front cover for the Reference: “Engine Front Cover Cleaning and following conditions: Inspection: ”.
Page 546 1D-206 Engine Mechanical: – Gouges or damage to the water pump seal area – Loose or damaged deadener plates (4) – Damage and/or corrosion to the engine coolant passage (6) – Damage to the crankshaft front oil seal bore – Gouges or damage to the O-ring sealing areas 3.
Page 547 Engine Mechanical: 1D-207 Camshaft Cover Disassemble Reference: “Camshaft Cover Removal - Left Side: ”. Reference: “Camshaft Cover Removal - Right Side: ”. Left Camshaft Cover 3. Remove the oil fill cap. 1. Remove and discard the left camshaft cover bolt grommets.
Page 548 1D-208 Engine Mechanical: 5. Remove and discard the left spark plug shield tube NOTE seals. Do not reuse the camshaft cover gasket and spark plug shield tube seals. Right Camshaft Cover 2. Remove and discard the right camshaft cover gasket. 1.
Page 549 Engine Mechanical: 1D-209 Camshaft Cover Cleaning and Inspection Reference: “Camshaft Cover Disassemble: ”. Cleaning Procedure 1. Clean the camshaft covers in solvent. WARNING Refer to “Safety Glasses Caution: ”. 2. Dry the camshaft covers with compressed air. Inspection Procedure 1. Inspect each camshaft cover for the dents or damage to the exterior.
Page 550 1D-210 Engine Mechanical: 5. Inspect the interior of the right camshaft cover for the 2. Apply sealant GM P/N 12378521 (Canadian P/N following conditions: 88901148) or equivalent to the NEW PCV orifice (1). – Restrictions to the ventilation system (1) –...
Page 551 Engine Mechanical: 1D-211 PCV Fitting Replacement 2. Install the NEW left camshaft cover gasket. NOTE If the PCV fitting is damaged or plugged and cannot be cleaned out, the PCV fitting can be replaced. 1. Remove the old PCV fitting. 2.
Page 552 1D-212 Engine Mechanical: Right Camshaft Cover CAUTION 1. Install the NEW right spark plug shield tube coil seals Refer to “Fastener Notice: ”. using the J 5590 (1) and J-25254-A (2). 4. Install the fuel injector sight shield cover ballstud. Tightening torque Tighten the fuel injector sight shield cover ball stud to 10 N⋅m (89 lb in).
Page 553 Engine Mechanical: 1D-213 NOTE The camshaft cover bolt grommet must be installed into the camshaft cover bolt hole before installing the camshaft cover bolt. 3. Install the NEW right camshaft cover bolt grommets. Reference: “Camshaft Cover Installation - Left Side: ”. Reference: “Camshaft Cover Installation - Right Side: ”.
Page 554 1D-214 Engine Mechanical: Upper Intake Manifold Disassemble Procedure 3. Remove and discard the throttle body gasket. 1. Remove the throttle body bolts. 4. Remove and discard the upper intake manifold expansion plugs, if required. 2. Remove the throttle body.
Page 555 Engine Mechanical: 1D-215 Lower Intake Manifold Disassemble Procedure 3. Remove the fuel injector rail. 1. Disconnect the fuel injector wiring harness connectors and remove the fuel injector wiring harness. 4. Remove the upper-to-lower intake manifold alignment pins. Reference: “Intake Manifold Cleaning and Inspection: ”. 2.
Page 556 1D-216 Engine Mechanical: Intake Manifold Cleaning and Inspection – Damage to the engine coolant air bleed pipe bracket mounting boss (7) Reference: “Intake Manifold Disassemble: ”. Upper Intake Manifold Cleaning Procedure 1. Remove any remaining gasket and/or gasket material from the following: –...
Page 557 Engine Mechanical: 1D-217 Inspection Procedure 4. Inspect the upper intake manifold sealing surface for warpage. 1. Inspect the lower intake manifold for the following conditions: a. Locate a straight edge across the upper-to-lower intake manifold sealing surface. – Damage, debris or restrictions to the lower intake manifold ports b.
Page 558 1D-218 Engine Mechanical: 3. Inspect the lower intake manifold sealing surfaces 2. Install the fuel injector rail. for warpage. a. Locate a straight edge across the lower intake manifold sealing surfaces. b. Insert a feeler gage between the lower intake manifold and the straight edge.
Page 559 Engine Mechanical: 1D-219 4. Install the fuel injector wiring harness and connect 2. Install the NEW throttle body gasket. the fuel injector wiring harness connectors. Upper Intake Manifold Assemble Procedure 3. Install the throttle body. 1. If removed, install the NEW expansion plugs into the upper intake manifold.
Page 560 1D-220 Engine Mechanical: 4. Install the throttle body bolts. 2. Install the upper intake manifold to the lower intake manifold. Tightening torque Tighten the throttle body bolts to 10 N⋅m (89 lb in). Upper to Lower Intake Manifold Assemble Procedure 3.
Page 561 Engine Mechanical: 1D-221 Thread Repair It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as Special tool the original hole. J 42385-700 High Feature Thread Repair Kit J 42385-2000 Thread Insert Kit J 43965 Thread Repair Extension Kit The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert.
Page 562 1D-222 Engine Mechanical: Standard Thread Repair - Flush Hole NOTE • During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill. • Do NOT drill any further than the original hole depth.
Page 563 Engine Mechanical: 1D-223 NOTE NOTE A properly counterbored hole will show a • During the tapping process, it is necessary slight burnishing on the surface of the base to repeatedly remove the tap and clean material for 360 degrees around the drilled chips from the hole and the flutes of the hole.
Page 564 1D-224 Engine Mechanical: NOTE NOTE All chips must be removed from the tapped All chips must be removed from the tapped hole prior to insert installation. hole prior to insert installation. 6. Using compressed air, clean out any chips. 8. Using compressed air, clean out any chips. 7.
Page 565 Engine Mechanical: 1D-225 10. Install the insert (2) onto the driver installation tool 12. Install the insert (2) into the tapped hole by hand (1). only. 11. Apply threadlock sealant GM P/N 12345493, NOTE (Canadian P/N 10953488), J 42385-109, LOCTITE If the insert will not thread down until the 277®...
Page 566 1D-226 Engine Mechanical: 16. Any installed insert that restricts or blocks an oil or NOTE engine coolant passage (3) will need to have the oil The driver installation tool will tighten up or engine coolant passage drilled out (4) to the before screwing completely through the original size of the oil or engine coolant passage.
Page 567 Engine Mechanical: 1D-227 Recessed Thread Repair NOTE WARNING • During the drilling process, it is necessary to repeatedly remove the drill and clean Refer to “Safety Glasses Caution: ”. chips from the hole and the flutes of the drill. NOTE •...
Page 568 1D-228 Engine Mechanical: 6. Spray cleaner GM P/N 12346139, GM P/N NOTE 12377981 (Canadian P/N 10953463) or equivalent • During the tapping process, it is necessary into the tapped hole. to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.
Page 569 Engine Mechanical: 1D-229 10. Apply threadlock sealant GM P/N 12345493, NOTE (Canadian P/N 10953488), J 42385-109, LOCTITE Do not allow oil or other foreign material to 277® or equivalent (1) to the insert OD threads (2). contact the outside diameter (OD) of the insert.
Page 570 1D-230 Engine Mechanical: 14. Inspect the insert (1) for proper installation (2) into NOTE the tapped hole. If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
Page 571 Engine Mechanical: 1D-231 Tapered Pipe Thread Repair NOTE The thread repair insert for tapered pipe threads is • During the drilling process, it is necessary coated with a clear silver zinc coating. to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
Page 572 1D-232 Engine Mechanical: NOTE NOTE All chips must be removed from the tapped • During the tapping process, it is necessary hole prior to insert installation. to repeatedly remove the tap and clean chips from the hole and the flutes of the 5.
Page 573 Engine Mechanical: 1D-233 9. Install the insert (2) onto the driver installation tool NOTE (1). All chips must be removed from the tapped hole prior to insert installation. 7. Using compressed air, clean out any chips. 10. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109, LOCTITE 277®...
Page 574 1D-234 Engine Mechanical: 11. Install the insert (2) into the tapped hole by hand NOTE only. The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
Page 575 Engine Mechanical: 1D-235 The cylinder head bolt hole thread repair tooling are in the kits J 42385-2000 and J 42385-700. The cylinder head bolt hole thread repair components consist of the following: • J 42385-723 Drill (1) • J 42385-724 Tap (2) •...
Page 576 1D-236 Engine Mechanical: 3. Position the alignment pin (1) through the bushing NOTE and into the cylinder head bolt hole. All chips must be removed from the drilled 4. With the alignment pin in the desired cylinder head hole prior to tapping. bolt hole, tighten the fixture retaining bolts (2).
Page 577 Engine Mechanical: 1D-237 9. In order to tap the new threads for the insert to the NOTE proper depth, rotate the tap into the cylinder head All chips must be removed from the tapped bolt hole until the mark (3) on the tap aligns with the hole prior to insert installation.
Page 578 1D-238 Engine Mechanical: 16. Install the insert (2) onto the driver installation tool NOTE (1). All chips must be removed from the tapped hole prior to insert installation. 14. Using compressed air, clean out any chips. 17. Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109, LOCTITE 277®;...
Page 579 Engine Mechanical: 1D-239 18. Install the insert and installation driver (1) into the Crankshaft Main Bolt Hole Thread Repair tapped hole by hand only. Special tool 19. Start the insert into the threaded hole. J 42385-700 High Feature Thread Repair Kit J 42385-2000 Thread Insert Kit NOTE If the insert will not thread down until the...
Page 580 1D-240 Engine Mechanical: Outboard Bolt Holes WARNING Refer to “Safety Glasses Caution: ”. NOTE • Ensure the fixture plate is installed during the machining and installation processes of the insert. • The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40®...
Page 581 Engine Mechanical: 1D-241 9. In order to tap the new threads for the insert to the NOTE proper depth, rotate the tap into the crankshaft main All chips must be removed from the drilled cap bolt hole until the mark (3) on the tap aligns with hole prior to tapping.
Page 582 1D-242 Engine Mechanical: 11. Spray cleaner GM P/N 12346139, GM P/N NOTE 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole. • Do not remove the fixture plate, ensure the fixture plate is installed during the installation process of the insert. •...
Page 583 Engine Mechanical: 1D-243 18. Install the insert until the flange of the insert contacts the counterbored surface. NOTE The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
Page 584 1D-244 Engine Mechanical: Inboard Bolt Holes WARNING Refer to “Safety Glasses Caution: ”. NOTE • Ensure the fixture plate is installed during the machining and installation processes of the insert. • The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40®...
Page 585 Engine Mechanical: 1D-245 9. In order to tap the new threads for the insert to the NOTE proper depth, rotate the tap into the crankshaft main All chips must be removed from the drilled cap bolt hole until the mark (3) on the tap aligns with hole prior to tapping.
Page 586 1D-246 Engine Mechanical: 11. Spray cleaner GM P/N 12346139, GM P/N NOTE 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole. • Do not remove the fixture plate, ensure the fixture plate is installed during the installation process of the insert. •...
Page 587 Engine Mechanical: 1D-247 18. Install the insert until the flange of the insert contacts the counterbored surface. NOTE The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
Page 588 1D-248 Engine Mechanical: Service Prior to Assembly 3. Ensure the NEW front oil gallery expansion plug is installed to the proper depth. • Dirt will cause premature wear of the rebuilt engine. Clean all the components. • Use the proper tools to measure the components when checking for excessive wear.
Page 589 Engine Mechanical: 1D-249 8. Apply thread sealant GM P/N 12346004 (Canadian 12. Apply thread sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent on the threads of the P/N 10953480) or equivalent on the threads of the M20 left side oil gallery threaded plug. M14 rear oil gallery threaded plug.
Page 590 1D-250 Engine Mechanical: 16. Apply thread sealant GM P/N 12346004 (Canadian 19. Install the NEW right front oil pan rail oil gallery P/N 10953480) or equivalent on the threads of the expansion plug. M14 right side oil gallery threaded plug. 20.
Page 591 Engine Mechanical: 1D-251 Crankshaft and Bearings Installation 4. Install the new lower crankshaft bearings into position in the main bearing caps. The lower Reference: “Crankshaft and Bearings Cleaning and crankshaft bearings are identified by NO grooves or Inspection: ”. holes. The bearings must fit flush with the crankshaft bearing caps.
Page 592 1D-252 Engine Mechanical: Crankshaft Bearing Clearance Measurement Procedure Special tool J 6125-1B Slide Hammer Adapter J 41818 Crankshaft Bearing Cap Remover J 45059 Angle Meter 6. Loosely install the original short/inner side main cap bolts. 7. Loosely install the original long/outer side main cap bolts.
Page 593 Engine Mechanical: 1D-253 12. Tighten the short/inner bolts (17-20). CAUTION Tightening torque Refer to “Fastener Notice: ”. Tighten the short/inner bolts to 30 N⋅m (22 lb ft) plus 60 degrees. 10. Tighten the inboard bolts (1-8). 13. Tighten the long/outer bolts (21-24). Tightening torque Tighten the inboard bolts to 20 N⋅m (15 lb ft) plus Tightening torque...
Page 594 1D-254 Engine Mechanical: 20. Compare your measurements with the “Engine Mechanical Specifications”. If the new bearings do not provide the proper crankshaft to bearing clearance, inspect the following: a. Re-measure the crankshaft journals for the correct specified size and ensure the proper new bearings are being installed.
Page 595 Engine Mechanical: 1D-255 24. Gently lower the crankshaft into position in the 26. Install the crankshaft main bearing caps. cylinder block. 27. Loosely install the original inner main cap bolts. 28. Loosely install the NEW outer main cap bolts. 25. Identify the proper order of the main bearing caps. The main bearing caps are numbered 1 (1) through 29.
Page 596 1D-256 Engine Mechanical: 33. Tighten the outboard bolts (9-16). NOTE Tightening torque The side main cap bolts originally have a Tighten the outboard bolts to 15 N⋅m (11 lb ft) sealant on the flange of the bolt head. NEW plus 110 degrees. bolts must be used.
Page 597 Engine Mechanical: 1D-257 Piston, Connecting Rod, and Bearing Installation Reference: “Piston and Connecting Rod Assemble: ”. Special tool EN 46111 Crankshaft Rotation Socket EN 46121 Connecting Rod Guide Pin Set J 8037 Ring Compressor J 43690 Rod Bearing Clearance Checking Tool J 43690-100 Rod Bearing Clearance Checking Tool - Adapter Kit J 45059 Angle Meter...
Page 598 1D-258 Engine Mechanical: 6. Using both hands, slowly guide the piston and connecting rod assembly into the cylinder from the top and bottom of the cylinder. DO NOT allow the connecting rod to contact the cylinder wall. 7. When the J 8037 contacts the deck surface, gently tap the piston into the cylinder using the handle end of a dead-blow hammer.
Page 599 Engine Mechanical: 1D-259 7. Allow the assembly to sit for at least 2 minutes. 8. Remove the connecting rod cap bolts. 9. Remove the connecting rod cap. J 43690 Rod Bearing Clearance Checking Tool • J 43690-20 Swivel Base (1) •...
Page 600 1D-260 Engine Mechanical: • J 43690-107 Cap (6) NOTE • J 43690-102 Foot (7) Reuse the old connecting rod bolts ONLY for measuring the connecting rod bearing • J 43690-101 Pivot Arm Assembly (8) clearance. • J 43690-103 Adapter (9) •...
Page 601 Engine Mechanical: 1D-261 11. During and after installation, ensure each piston is 5. Install the NEW connecting rod bolts into the positioned properly in the correct cylinder. The connecting rod cap. locating arrow on the top of each piston must be Tightening torque pointing toward the front of the engine.
Page 602 1D-262 Engine Mechanical: 2. Install the EN-47839 with the J 42183 (1, 2) onto the NOTE rear of the crankshaft flange. DO NOT allow any engine oil on the area where the crankshaft rear oil seal housing is to be installed. 4.
Page 603 Engine Mechanical: 1D-263 Cylinder Head Installation - Right Side Reference: “Cylinder Head Assemble: ”. Special tool EN 46111 Crankshaft Rotation Socket J 45059 Angle Meter NOTE Ensure that the crankshaft is in the timing drive assembly position using the EN 46111. 1.
Page 604 1D-264 Engine Mechanical: Valve Lifter Installation - Right Side Reference: “Valve Lifters Cleaning and Inspection: ”. CAUTION Refer to “Fastener Notice: ”. NOTE Do not stroke/cycle the stationary hydraulic NOTE lash adjuster plunger without oil in the lower DO NOT allow oil on the cylinder head bolt pressure chamber.
Page 605 Engine Mechanical: 1D-265 4. Apply a liberal amount of lubricant GM P/N 3. The rounded head end of the follower goes on the 12345501 (Canadian P/N 992704) or equivalent to SHLA while the flat end goes on the valve tip. the SHLA pivot spheres.
Page 606 1D-266 Engine Mechanical: 3. Select the proper camshaft for the particular 5. Place the right intake and right exhaust camshafts in installation location. The ring placement is defined as position in the right cylinder head. follows: a. The number 2 identification ring for the right exhaust camshaft is machined off (1) - Third Design, Camshaft Timing Drive System.
Page 607 Engine Mechanical: 1D-267 7. Observe the markings on the right cylinder head CAUTION camshaft bearing caps. Each bearing cap is marked Refer to “Fastener Notice: ”. in order to identify its location. The markings have the following meanings: 12. Tighten the camshaft bearing cap bolts in the –...
Page 608 1D-268 Engine Mechanical: 5. Install new M11 cylinder head bolts. Tightening torque 1. Tighten the M11 cylinder head bolts a first pass in sequence to 45 N⋅m (33 lb ft). 2. Tighten the M11 cylinder head bolts a second pass in sequence an additional 120 degrees using the J 45059.
Page 609 Engine Mechanical: 1D-269 3. Install the SHLAs in the cylinder head. NOTE 4. Apply a liberal amount of lubricant GM P/N The follower must be positioned squarely on 12345501 (Canadian P/N 992704) or equivalent to the valve tip so that the full width of the roller the SHLA pivot spheres.
Page 610 1D-270 Engine Mechanical: Camshaft Installation - Left Side Reference: “Camshaft Cleaning and Inspection: ”. Special tool EN 46111 Crankshaft Rotation Socket 3. Select the proper camshaft for the particular installation location. The ring placement is defined as follows: a. The number 4 identification ring for the left intake camshaft is machined off (1) - Third Design, 1.
Page 611 Engine Mechanical: 1D-271 5. Place the left intake and left exhaust camshafts in 7. Observe the markings on the left cylinder head position in the left cylinder head. camshaft bearing caps. Each bearing cap is marked in order to identify its location. The markings have the following meanings: –...
Page 612 1D-272 Engine Mechanical: Camshaft Position Actuator Installation - Right Side Intake (Third Design) Reference: “Camshaft Timing Drive Components Cleaning and Inspection (Third Design): ”. CAUTION Refer to “Fastener Notice: ”. 12. Tighten the camshaft bearing cap bolts in the 1. Ensure the proper camshaft position actuator is sequence shown.
Page 613 Engine Mechanical: 1D-273 4. Install the right intake camshaft position actuator. CAUTION CAUTION Ensure the proper camshaft position actuator is installed in the correct position. Failure to Refer to “Fastener Notice: ”. install the proper camshaft position actuator can effect engine performance and set an 5.
Page 614 1D-274 Engine Mechanical: Reference: “Camshaft Position Actuator Installation - Right Side Exhaust (Fourth Design): ”. Camshaft Position Actuator Installation - Right Side Exhaust (Third Design) 4. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the triangle marking (2).
Page 615 Engine Mechanical: 1D-275 2. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the triangle marking (2). The marking is for alignment to the highlighted timing chain link on the right side of the engine.
Page 616 1D-276 Engine Mechanical: Camshaft Position Actuator Installation - CAUTION Left Side Intake (Third Design) Refer to “Fastener Notice: ”. 5. Install the camshaft position actuator bolt. Tightening torque Tighten the camshaft position actuator bolt to 58 N⋅m (43 lb ft). Reference: “Camshaft Position Actuator Installation - Left Side Exhaust (Third Design): ”.
Page 617 Engine Mechanical: 1D-277 4. Ensure the proper timing mark is used. Observe the CAUTION outer ring of the camshaft position actuator for the Ensure the proper camshaft position actuator circle marking (1). The circle marking is for alignment is installed in the correct position. Failure to to the highlighted timing chain link on the left side of install the proper camshaft position actuator the engine.
Page 618 1D-278 Engine Mechanical: Camshaft Position Actuator Installation - CAUTION Left Side Exhaust (Third Design) Refer to “Fastener Notice: ”. 5. Install the camshaft position actuator bolt. Tightening torque Tighten the camshaft position actuator bolt to 58 N⋅m (43 lb ft). Reference: “Crankshaft Sprocket Installation (Third Design): ”.
Page 619 Engine Mechanical: 1D-279 4. Install the left exhaust camshaft position actuator. 2. Install the crankshaft sprocket on to the nose of the crankshaft. CAUTION 3. Align the notch in the crankshaft sprocket with the Refer to “Fastener Notice: ”. pin in the crankshaft. 4.
Page 620 1D-280 Engine Mechanical: Crankshaft Sprocket Installation (Fourth Design) Special tool EN 46111 Crankshaft Rotation Socket 5. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) aligned to the stage one timing mark on the oil pump cover (2) using the EN 46111.
Page 621 Engine Mechanical: 1D-281 1. Ensure that the left camshaft intermediate drive chain idler (2) is being installed. The recessed hub (3) and the larger sprocket of the left camshaft intermediate drive chain idler is installed outward. The raised hub and the smaller sprocket of the left camshaft intermediate drive chain idler is installed towards the block.
Page 622 1D-282 Engine Mechanical: Secondary Camshaft Drive Chain 3. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) Installation - Left Side (Third Design) aligned to the stage one timing mark on the oil pump Special tool cover (2) using the EN 46111.
Page 623 Engine Mechanical: 1D-283 6. Wrap the secondary camshaft drive chain around 9. Align the left intake camshaft position actuator both left actuator drive sprockets. sprocket alignment circle mark (1) with the timing camshaft drive chain link (2). 7. Ensure there are 7 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.
Page 624 1D-284 Engine Mechanical: Secondary Camshaft Drive Chain 3. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) Installation - Left Side (Fourth Design) aligned to the stage one timing mark on the oil pump Special tool cover (2) using the EN 46111.
Page 625 Engine Mechanical: 1D-285 6. Wrap the secondary camshaft drive chain around 9. Align the left intake camshaft position actuator both left actuator drive sprockets. sprocket alignment circle mark (1) with the timing camshaft drive chain link (2). 7. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.
Page 626 1D-286 Engine Mechanical: Secondary Camshaft Drive Chain Guide Secondary Camshaft Drive Chain Guide Installation - Left Side (Third Design) Installation - Left Side (Fourth Design) 1. Ensure that the left secondary camshaft drive chain 1. Ensure that the left secondary camshaft drive chain guide (2) is being installed.
Page 627 Engine Mechanical: 1D-287 Secondary Camshaft Drive Chain Shoe Installation - Left Side (Third Design) CAUTION Refer to “Fastener Notice: ”. 1. Ensure that the left secondary camshaft drive chain shoe (2) is being installed. 3. Install the secondary camshaft drive chain shoe bolt. Tightening torque Tighten the secondary camshaft drive chain shoe bolt to 23 N⋅m (17 lb ft).
Page 628 1D-288 Engine Mechanical: Secondary Camshaft Drive Chain Tensioner Installation - Left Side (Third Design) Special tool EN 46112 Tensioner Retraction Pins J 45027 Tensioner Tool 2. Position the left secondary camshaft drive chain shoe. 1. Ensure that the left secondary camshaft drive chain tensioner (2) is being installed.
Page 629 Engine Mechanical: 1D-289 3. Install the plunger into the left secondary camshaft 6. Install a NEW left secondary camshaft drive chain drive chain tensioner body. tensioner gasket to the left secondary camshaft drive chain tensioner. 7. Install the left secondary camshaft drive chain tensioner bolts through the left secondary camshaft drive chain tensioner and gasket.
Page 630 1D-290 Engine Mechanical: 12. Verify the left secondary camshaft drive chain timing CAUTION mark alignments (1-6). Also refer to “Camshaft Refer to “Fastener Notice: ”. Timing Drive Chain Alignment Diagram (Third Design)” “Camshaft Timing Drive Chain Alignment 10. Verify the proper placement of the left secondary Diagram (Fourth Design)”- Stage One.
Page 631 Engine Mechanical: 1D-291 2. Using the J 45027, reset the left secondary camshaft 4. Compress the plunger into the body and lock the left drive chain tensioner plunger. secondary camshaft drive chain tensioner by inserting the EN 46112 into the access hole in the side of the left secondary camshaft drive chain tensioner body.
Page 632 1D-292 Engine Mechanical: 9. Place the left secondary camshaft drive chain 11. Release the left secondary camshaft drive chain tensioner into position and loosely install the bolts to tensioner by pulling out the EN 46112 and unlocking the block. the tensioner plunger. 12.
Page 633 Engine Mechanical: 1D-293 Camshaft Intermediate Drive Chain Idler 3. Install the camshaft intermediate drive chain idler bolt. Installation - Right Side (Third Design) Tightening torque Tighten the camshaft intermediate drive chain idler bolt to 58 N⋅m (43 lb ft). Reference: “Primary Camshaft Drive Chain Installation (Third Design): ”.
Page 634 1D-294 Engine Mechanical: 2. Install the right camshaft intermediate drive chain 2. Wrap the primary camshaft drive chain around the idler. large sprockets of each camshaft intermediate drive chain idler and the crankshaft sprocket. CAUTION Refer to “Fastener Notice: ”. 3.
Page 635 Engine Mechanical: 1D-295 4. The right camshaft intermediate drive chain idler 6. Ensure all the timing marks (2, 3, 6) are properly timing mark (2) will align with a timing camshaft drive aligned with the timing camshaft drive chain links (1, chain link (1).
Page 636 1D-296 Engine Mechanical: 2. Wrap the primary camshaft drive chain around the 4. The right camshaft intermediate drive chain idler large sprockets of each camshaft intermediate drive timing mark (2) will align with a timing camshaft drive chain idler and the crankshaft sprocket. chain link (1).
Page 637 Engine Mechanical: 1D-297 2. Install the primary camshaft drive chain lower guide bolts. Tightening torque Tighten the primary camshaft drive chain lower guide bolts to 23 N⋅m (17 lb ft). Reference: “Primary Camshaft Drive Chain Guide Installation - Upper (Third Design): ”. Primary Camshaft Drive Chain Guide Installation - Lower (Fourth Design) Ensure all the timing marks (2, 3, 6) are properly...
Page 638 1D-298 Engine Mechanical: Primary Camshaft Drive Chain Guide Primary Camshaft Drive Chain Guide Installation - Upper (Third Design) Installation - Upper (Fourth Design) 1. Ensure the upper primary camshaft drive chain guide 1. Ensure the upper primary camshaft drive chain guide (3) is being installed.
Page 639 Engine Mechanical: 1D-299 Primary Camshaft Drive Chain Tensionser Installation (Third Design) Special tool EN 46105 Camshaft Locking Tool EN 46111 Crankshaft Rotation Socket EN 46112 Tensioner Retraction Pins J 45027 Tensioner Tool 3. Install the plunger into the primary camshaft drive chain tensioner body.
Page 640 1D-300 Engine Mechanical: 6. Install a NEW primary camshaft drive chain CAUTION tensioner gasket to the primary camshaft drive chain Refer to “Fastener Notice: ”. tensioner. 7. Install the primary camshaft drive chain tensioner 10. Verify the proper placement of the primary camshaft bolts through the primary camshaft drive chain drive chain tensioner gasket tab (1).
Page 641 Engine Mechanical: 1D-301 12. Verify the primary and left secondary camshaft drive 14. Using the EN 46111, rotate the crankshaft and chain timing mark alignments (1-12). Also refer to crankshaft sprocket from the stage 1 alignment “Camshaft Timing Drive Chain Alignment Diagram position (1) to the stage 2 alignment position (2), 115 (Third Design)”...
Page 642 1D-302 Engine Mechanical: 16. Install the EN 46105-1 onto the rear of the right 2. Using the J 45027, reset the primary camshaft drive camshafts. chain tensioner plunger. Reference: “Secondary Camshaft Drive Chain Installation - Right Side (Third Design): ”. Primary Camshaft Drive Chain Tensionser Installation (Fourth Design) Special tool...
Page 643 Engine Mechanical: 1D-303 4. Compress the plunger into the body and lock the 9. Place the primary camshaft drive chain tensioner primary camshaft drive chain tensioner by inserting into position and loosely install the bolts to the block. the EN 46112 into the access hole in the side of the primary camshaft drive chain tensioner body.
Page 644 1D-304 Engine Mechanical: 11. Release the primary camshaft drive chain tensioner 13. Remove the EN 46105-1 from the rear of the left by pulling out the EN 46112 and unlocking the camshafts. tensioner plunger. 14. Using the EN 46111, rotate the crankshaft and 12.
Page 645 Engine Mechanical: 1D-305 Secondary Camshaft Drive Chain Installation - Right Side (Third Design) 15. Install the EN 46105-2 onto the rear of the left camshafts. 1. Ensure that the crankshaft is in the stage 2 timing drive assembly position (1). 16.
Page 646 1D-306 Engine Mechanical: 3. Place the secondary camshaft drive chain around 6. Align the right exhaust camshaft position actuator the right camshaft intermediate drive chain idler sprocket alignment triangle mark (1) with the timing outer sprocket, aligning the timing camshaft drive camshaft drive chain link (2).
Page 647 Engine Mechanical: 1D-307 8. There will be 18 links (1) between the right camshaft 2. Install the right secondary camshaft drive chain. intermediate drive chain idler timing camshaft drive chain link and each right camshaft position actuator sprocket timing camshaft drive chain link. Reference: “Secondary Camshaft Drive Chain Guide Installation - Right Side (Third Design): ”.
Page 648 1D-308 Engine Mechanical: 4. Wrap the secondary camshaft drive chain around 7. Align the right intake camshaft position actuator both right actuator drive sprockets. sprocket alignment triangle mark (2) with the timing camshaft drive chain link (1). 5. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.
Page 649 Engine Mechanical: 1D-309 Secondary Camshaft Drive Chain Guide Secondary Camshaft Drive Chain Guide Installation - Right Side (Third Design) Installation - Right Side (Fourth Design) 1. Ensure that the right secondary camshaft drive chain 1. Ensure that the right secondary camshaft drive chain guide (1) is being installed.
Page 650 1D-310 Engine Mechanical: Secondary Camshaft Drive Chain Shoe Installation - Right Side (Third Design) CAUTION Refer to “Fastener Notice: ”. 1. Ensure that the right secondary camshaft drive chain shoe (1) is being installed. 3. Install the secondary camshaft drive chain shoe bolt. Tightening torque Tighten the secondary camshaft drive chain shoe bolt to 23 N⋅m (17 lb ft).
Page 651 Engine Mechanical: 1D-311 Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Third Design) Special tool EN 46112 Tensioner Retraction Pins J 45027 Tensioner Tool 2. Position the right secondary camshaft drive chain shoe. 1. Ensure that the right secondary camshaft drive chain tensioner (1) is being installed.
Page 652 1D-312 Engine Mechanical: 3. Install the plunger into the right secondary camshaft 6. Install a NEW right secondary camshaft drive chain drive chain tensioner body. tensioner gasket to the right secondary camshaft drive chain tensioner. 7. Install the right secondary camshaft drive chain tensioner bolts through the right secondary camshaft drive chain tensioner and gasket.
Page 653 Engine Mechanical: 1D-313 CAUTION CAUTION Refer to “Fastener Notice: ”. Ensure that all timing chain tensioners are completely released. A timing chain 10. Verify the proper placement of the right secondary tensioner that is not properly released can camshaft drive chain tensioner gasket tab (1). lead to serious engine damage.
Page 654 1D-314 Engine Mechanical: Secondary Camshaft Drive Chain Tensioner Installation - Right Side (Fourth Design) Special tool EN 46112 Tensioner Retraction Pins J 45027 Tensioner Tool 3. Install the plunger into the right secondary camshaft drive chain tensioner body. 1. Ensure that the right secondary camshaft drive chain tensioner (1) is being installed.
Page 655 Engine Mechanical: 1D-315 6. Install a NEW right secondary camshaft drive chain CAUTION tensioner gasket to the right secondary camshaft Refer to “Fastener Notice: ”. drive chain tensioner. 7. Install the right secondary camshaft drive chain 10. Verify the proper placement of the right secondary tensioner bolts through the right secondary camshaft camshaft drive chain tensioner gasket tab (1).
Page 656 1D-316 Engine Mechanical: 1. Install the 8 mm (0.315 in) guide from the EN 46109 into the cylinder block positions as shown. CAUTION Ensure that all timing chain tensioners are 2. Install the NEW engine front cover to cylinder block completely released.
Page 657 Engine Mechanical: 1D-317 4. Place the engine front cover onto the EN 46109 and CAUTION slide into position. Refer to “Fastener Notice: ”. 5. Remove the EN 46109 from the cylinder block. 7. Loosely install the engine front cover bolts to hold the engine front cover deadener into position.
Page 658 1D-318 Engine Mechanical: 9. Tighten the engine front cover bolts in the sequence 12. Install NEW O-rings on the camshaft position sensor. shown (1-22). 13. Place the camshaft position sensors in position on the front cover. Tightening torque 14. Install the camshaft position sensor bolts. Tighten the engine front cover bolts in the sequence to 23 N⋅m (17 lb ft).
Page 659 Engine Mechanical: 1D-319 2. Install the NEW engine front cover to cylinder block 4. Place the engine front cover onto the EN 46109 and seal. slide into position. 5. Remove the EN 46109 from the cylinder block. 3. Place a 3 mm (0.118 in) bead of RTV sealant, GM P/ N 12378521 (Canadian P/N 88901148) or 6.
Page 660 1D-320 Engine Mechanical: 9. Tighten the engine front cover bolts in the sequence CAUTION shown (1-22). Refer to “Fastener Notice: ” Tightening torque Tighten the engine front cover bolts in the 7. Loosely install the engine front cover bolts to hold sequence to 23 N⋅m (17 lb ft).
Page 661 Engine Mechanical: 1D-321 12. Install NEW O-rings on the camshaft position sensor. 2. Install the EN 46101 onto the spark plug tubes of the left cylinder head. 13. Place the camshaft position sensors in position on the front cover. 14. Install the camshaft position sensor bolts. Tightening torque Tighten the camshaft position sensor bolts to 10 N⋅m (89 lb in).
Page 662 1D-322 Engine Mechanical: 5. Place a bead 8 mm (0.3150 in) in diameter by 4 mm 7. Loosely install the left camshaft cover bolts. (0.1575 in) in height of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover split lines (1). CAUTION Refer to “Fastener Notice: ”.
Page 663 Engine Mechanical: 1D-323 9. Remove the EN 46101 from the spark plug tubes of 11. Install the ignition coils. the left cylinder head. 12. Install the ignition coil bolts. 10. Install the NEW spark plugs into the left cylinder Tightening torque head.
Page 664 1D-324 Engine Mechanical: Camshaft Cover Installation - Right Side Reference: “Camshaft Cover Assemble: ”. Special tool EN 46101 Spark Plug Tube Seal Guide EN 46105 Camshaft Locking Tool 3. Install the camshaft cover bolt grommets prior to installing the camshaft cover bolts. 4.
Page 665 Engine Mechanical: 1D-325 6. Place the right camshaft cover into position onto the CAUTION right cylinder head. Refer to “Fastener Notice: ”. 8. Tighten the right camshaft cover bolts in the sequence shown. Tightening torque Tighten the right camshaft cover bolts in the sequence to 10 N⋅m (89 lb in).
Page 666 1D-326 Engine Mechanical: 10. Install the NEW spark plugs into the right cylinder 12. Install the ignition coil bolts. head. Tightening torque Tightening torque Tighten the ignition coil bolt to 10 N⋅m (89 lb in). Tighten the spark plugs to 20 N⋅m (15 lb ft). Reference: “Intake Manifold Installation: ”.
Page 667 Engine Mechanical: 1D-327 2. Install the intake manifold assembly. 4. Loosely install the long intake manifold bolts. Tightening torque Tighten all of the intake manifold bolts to 23 N⋅m (17 lb ft). CAUTION Refer to “Fastener Notice: ”. 5. Install the evaporative emissions (EVAP) solenoid. 3.
Page 668 1D-328 Engine Mechanical: 6. Install the EVAP solenoid bolt 8. Install and connect the dirty air positive crankcase ventilation (PCV) hose to the intake manifold and to Tightening torque the right camshaft cover fitting. Tighten the EVAP solenoid bolt to 10 N⋅m (89 lb in).
Page 669 Engine Mechanical: 1D-329 10. Install the fuel injector harness connector to the Engine Flywheel Installation engine coolant air bleed pipe bracket. Reference: “Engine Flywheel Cleaning and Inspection: ”. Special tool EN 46106 Engine Flywheel Holding Tool J 45059 Angle Meter 11.
Page 670 1D-330 Engine Mechanical: Crankshaft Balancer Installation Reference: “Crankshaft Balancer Cleaning and Inspection: ”. Special tool EN 46106 Engine Flywheel Holding Tool J 41998-B Crankshaft Balancer Installer J 45059 Angle Meter 3. Install the EN 46106. 1. The EN 46106 must be installed onto the flywheel. 2.
Page 671 Engine Mechanical: 1D-331 4. Place the crankshaft balancer in position on the 10. Remove the EN 46106. crankshaft. Reference: “Oil Filter Adapter Installation: ”. 5. Thread the J 41998-B in the crankshaft. Ensure you engage at least 10 threads of the J 41998-B before Drive Belt Tensioner Installation pressing the crankshaft balancer in place.
Page 672 1D-332 Engine Mechanical: Engine Prelubing Special tool EN-47971 Oil Pressure Gage Adapter J 45299 Engine Preluber 3. Install the 1/8 NPT fitting from the J 45299 into the port on the EN-47971. NOTE Ensure the oil cooler lines are disconnected and the oil filter adapter oil cooler line ports are blocked in order to direct the oil from the engine preluber into the engine.
Page 673 Engine Mechanical: 1D-333 NOTE A constant and continuous flow of clean engine oil is required in order to properly prime the engine. Use the approved engine oil as specified in the owner’s manual. 6. Pump the handle of the J 45299 in order to flow a minimum of 1-1.9 liters (1-2 quarts) of fresh clean engine oil.
Page 674 1D-334 Engine Mechanical: Specifications Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7) Specification Application Metric English Camshaft Position Actuator Camshaft Bolt 58 N⋅m 43 lb ft Oil Control Valve Bolt 10 N⋅m 89 lb in Camshaft Cap Bolt 10 N⋅m 89 lb in Camshaft Cover Bolt 10 N⋅m...
Page 675 Engine Mechanical: 1D-335 Specification Application Metric English Oil Filter 25 N⋅m 18 lb ft Oil Gallery Plug 31 N⋅m 23 lb ft PCV Tube Bracket Bolt/Ball Stud 10 N⋅m 89 lb in Piston Oil Cooling Nozzle Bolt 10 N⋅m 89 lb in Primary Camshaft Drive Chain Left Lower Guide Bolt - Oil Pump - Second Design 23 N⋅m...
Page 676 1D-336 Engine Mechanical: Specification Application Metric English Camshaft Journal Diameter - Front Number 1 34.936-34.960 mm 1.3754-1.3764 in Camshaft Journal Diameter - Middle and Rear Number 2-4 26.936-26.960 mm 1.0605-1.0614 in Camshaft Journal Out-of-Round 0.006 mm 0.0002 in Camshaft Journal to Bore Clearance 0.040-0.084 mm 0.0016-0.0033 in Camshaft Lobe Duration - Exhaust @ 0.150 mm (0.0059 in) Lift...
Page 677 Engine Mechanical: 1D-337 Specification Application Metric English Crankshaft Runout 0.030 mm 0.0012 in Crankshaft Thrust Bearing Clearance 0.076-0.305 mm 0.0030-0.0120 in Crankshaft Thrust Surface - Height Diameter 95.000 mm 3.7401 in Crankshaft Thrust Surface Runout 0.040 mm 0.0016 in Cylinder Head Combustion Chamber Volume 53.407 cc 3.259 cu in...
Page 678 1D-338 Engine Mechanical: Specification Application Metric English Valve Face Width - Exhaust 2.750 mm 0.1083 in Valve Face Width - Intake 2.180 mm 0.0858 in Valve Head Diameter - Exhaust 30.470-30.730 mm 1.1996-1.2098 in Valve Head Diameter - Intake 36.830-37.090 mm 1.4500-1.4602 in Valve Installed Height 35.23-36.69 mm...
Page 679 Engine Mechanical: 1D-339 Thread Repair Specifications Left Cylinder Head Camshaft Cover Face Left Cylinder Head Camshaft Cover Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 0.885 0.708 M6 x 1.0...
Page 680 1D-340 Engine Mechanical: Left Cylinder Head Front Face Left Cylinder Head Front Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M8 x 1.25 THRU THRU M12 x 1.574 1.279...
Page 681 Engine Mechanical: 1D-341 Left Cylinder Head Intake Face Left Cylinder Head Intake Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.122 0.905 M8 x 1.25 28.5 23.0...
Page 682 1D-342 Engine Mechanical: Left Cylinder Head Exhaust Face Left Cylinder Head Exhaust Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0 1.082...
Page 683 Engine Mechanical: 1D-343 Left Cylinder Head Rear Face Left Cylinder Head Rear Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0...
Page 684 1D-344 Engine Mechanical: Right Cylinder Head Camshaft Cover Face Right Cylinder Head Camshaft Cover Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M6 x 1.0 THRU THRU 1.122...
Page 685 Engine Mechanical: 1D-345 Right Cylinder Head Front Face Right Cylinder Head Front Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M8 x 1.25 THRU THRU 0.888 0.708 M6 x 1.0...
Page 686 1D-346 Engine Mechanical: Right Cylinder Head Intake Face Right Cylinder Head Intake Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.122 0.905 M8 x 1.25 28.5 23.0...
Page 687 Engine Mechanical: 1D-347 Right Cylinder Head Exhaust Face Right Cylinder Head Exhaust Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 0.885 0.000 M6 x 1.0 22.5 18.0 1.318...
Page 688 1D-348 Engine Mechanical: Right Cylinder Head Rear Face Right Cylinder Head Rear Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0...
Page 689 Engine Mechanical: 1D-349 Engine Block Front Engine Block Front Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.122 0.905 M8 x 1.25 28.5 23.0 1.318 1.063 M10 x 1.5 33.5 27.0...
Page 690 1D-350 Engine Mechanical: Engine Block Left Side Engine Block Left Side Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.122 0.905 M8 x 1.25 28.5 23.0 1.181 0.787 M20 x 1.5...
Page 691 Engine Mechanical: 1D-351 Engine Block Right Side Engine Block Right Side Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 0.885 0.708 M6 x 1.0 22.5 18.0 1.122 0.905 M8 x 1.25...
Page 692 1D-352 Engine Mechanical: Engine Block Rear Engine Block Rear Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.319 1.063 M10 x 1.5 33.5 27.0 0.885 0.708 M6 x 1.0 22.5 18.0...
Page 693 Engine Mechanical: 1D-353 Engine Block Bottom Engine Block Bottom Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 2.204 1.929 M10 x 2.0 56.0 49.0 1.594 M8 x 1.25 46.0 1.8110 40.5 1.122 0.905...
Page 694 1D-354 Engine Mechanical: Engine Block Left Deck Face Engine Block Left Deck Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.122 0.905 M8 x 1.25 28.5 23.0 4.035...
Page 695 Engine Mechanical: 1D-355 Engine Block Right Deck Face Engine Block Right Deck Face Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 4.035 3.700 M11 x 2.0 102.5 94.0 1.122...
Page 696 1D-356 Engine Mechanical: Engine Front Cover Engine Front Cover Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M6 x 1.0 THRU THRU 0.846 0.708 M6 x 1.0 21.5 18.0 1.122...
Page 697 Engine Mechanical: 1D-357 Upper Intake Manifold - Top Upper Intake Manifold - Top Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M6 x 1.0 THRU THRU 0.885 0.708 M6 x 1.0...
Page 698 1D-358 Engine Mechanical: Upper Intake Manifold - Front Upper Intake Manifold - Front Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M6 x 1.0 THRU THRU...
Page 699 Engine Mechanical: 1D-359 Lower Intake Manifold - Top Lower Intake Manifold - Top Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M6 x 1.0 THRU THRU M8 x 1.25 THRU THRU...
Page 700 1D-360 Engine Mechanical: Oil Pan Front Oil Pan Front Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0 M12 x 1.555 1.259 39.5...
Page 701 Engine Mechanical: 1D-361 Oil Pan Left Side Oil Pan Left Side Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0...
Page 702 1D-362 Engine Mechanical: Oil Pan Right Side Oil Pan Right Side Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) M12 x THRU THRU 1.75 1.122 0.905 M8 x 1.25 28.5 23.0...
Page 703 Engine Mechanical: 1D-363 Oil Pan Rear Oil Pan Rear Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.318 1.063 M10 x 1.5 33.5 27.0...
Page 704 1D-364 Engine Mechanical: Oil Pan Top Oil Pan Top Hole Thread Counter Stop Drill Depth Tap Depth Drill Driver Insert Location Size Bore Tool Collar (Maximum) (Minimum) J 42385- (IN) (IN) 1.102 0.925 M6 x 1.0 28.0 23.5...
Page 705 Engine Mechanical: 1D-365 Special Tools and Equipment Engine Support Fixture Installation Procedure Special tool J 28467-B Universal Engine Support Fixture J-28467-13 Engine Support Fixture Adapters J 42451-1 Engine Support Adapter J 36462-A Engine Support Adapter Leg Set J 28467-7A Bolt Hook J 28467-34 Lift Hook Wing Nut &...
Page 706 1D-366 Engine Mechanical: 8. Position two 58 cm (23 in) engine support fixture 11. Install the lift hook and bracket assembly (1) to the cross bars (1) longitudinally with two J 36462-A leg longitudinal mounted cross bar (2). assembly (2). 9.
Page 707 Engine Mechanical: 1D-367 13. Assemble the lift hook wing nut J-28467-34 and the 15. Position the J 28467-7A bolt hook (1) to the front lift hook bracket J-28467-6A to the lift hook J-28467- engine lift bracket J-42451-1 (2). 16. Evenly tighten both wing nuts J-28467-34 (1) until 14.
Page 708 1D-368 Engine Mechanical: Tools and Equipment Illustration Tool Number/Description • Special tools are listed and illustrated throughout this section, with a complete listing at the end of the section. These tools, or their equivalents, are designed to quickly and safely accomplish the operations for which they are intended.
Page 709 Engine Mechanical: 1D-369 Illustration Tool Number/Description Illustration Tool Number/Description EN 46111 EN 46121 Crankshaft Rotation Connecting Rod Guide Pin Socket EN 46122 EN 46112 Camshaft Position Tensioner Retraction Pins Actuator Check-Ball Valve Remover/Installer EN 46116 EN 46745 Valve Stem Seal Remover/ Piston Pin Clip Remover/ Installer Installer...
Page 710 1D-370 Engine Mechanical: Illustration Tool Number/Description Illustration Tool Number/Description EN 48313 J 8001 Timing Chain Retention Dial Indicator Set Tool GE 48326 J 8037 Sealant Dispenser Ring Compressor J 8062 J 5590 Valve Spring Compressor - Bearing and Seal Driver Head Off J 6125-1B J 8087...
Page 711 Engine Mechanical: 1D-371 Illustration Tool Number/Description Illustration Tool Number/Description J 22738-B J 28467-7A Valve Spring Tester Bolt Hook J 28467-34 J 25254-A Lift Hook Wing Nut and Oil Seal Installer Washer J 28410 J 29184 Gasket Remover Oil Seal Installer J 28467 J 35667-A Engine Support Fixture...
Page 712 1D-372 Engine Mechanical: Illustration Tool Number/Description Illustration Tool Number/Description J 38416-2 J 42096 Crankshaft Button Valve Guide Reamer J 39313 J 42183 Spark Plug Port Adapter Handle J 41816 J 42385-700 Crankshaft Balancer High Feature Thread Remover Repair Kit J 41818 J 42385-2000 Crankshaft Bearing Cap Thread Insert Kit...
Page 713 Engine Mechanical: 1D-373 Illustration Tool Number/Description Illustration Tool Number/Description J 43690 J 45059 Rod Bearing Clearance Angle Meter Checking Tool J 43690-100 J 45299 Rod Bearing Clearance Engine Preluber Checking Tool - Adapter Kit Special Tools - Engine Controls - 3.6L (LY7) Illustration Tool Number/Description J 43965...
Page 714 1E-1 Engine Lubrication System: Engine Lubrication System General Description Lubrication Description A structural diecast aluminum oil pan incorporates an oil suction tube, a baffle, a windage tray and an oil level sensor. The oil suction tube is bolted into the oil pan and seals to the bottom of the block with O-ring gasket. The baffle is mounted to the lower portion of the 6-quart capacity oil pan sump and ensures oil supply to the oil suction pickup.
Page 715 Engine Lubrication System: 1E-2 Diagnostic Information and Procedures Oil Consumption Diagnosis Checks Causes DEFINITION: Excessive oil consumption (not due to leaks) is the use of 0.946 L (1 qt) or more of engine oil within 3 200 km (2,000 mi). The causes of excessive oil consumption may include the following conditions: Preliminary •...
Page 716 1E-3 Engine Lubrication System: 9. Install the J 21867 flexible hose to the EN-47971. CAUTION 10. Run the engine and measure the engine oil Special new tool EN 47971 must be used. Due pressure. to the special size and thread pitch of the oil 11.
Page 717 Engine Lubrication System: 1E-4 – Plugged or incorrect oil filter and/or malfunctioning CAUTION oil bypass valve. Refer to “Engine Oil and Oil Filter This engine uses a special high performance Replacement”. oil filter. Use of any other filter may lead to –...
Page 718 1E-5 Engine Lubrication System: Checks Action Black Light and Dye Method 1. A dye and light kit is available for finding leaks. Use the J 28428-E High- Intensity Black Light Kit or equivalent. Refer to the manufacturer's instructions when using the tool. 2.
Page 719 Engine Lubrication System: 1E-6 Engine Oil and Oil Filter Replacement Installation Procedure Removal Procedure 1. Lubricate the NEW oil filter gasket with clean engine oil. 1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”. 2. Tighten the oil filter. 2.
Page 720 1E-7 Engine Lubrication System: 1. Position a NEW oil filter adapter gasket onto the oil filter adapter. 4. Remove the oil filter adapter. 2. Place the oil filter adapter into position. 5. Remove and discard the oil filter adapter gasket. Installation Procedure CAUTION Refer to “Fastener Notice: ”.
Page 721 Engine Lubrication System: 1E-8 Engine Oil Pressure Sensor and/or Switch Oil Pan Replacement Replacement Special tool Removal Procedure EN 46109 Guide Pin Set Removal Procedure 1. Disconnect the battery negative cable. Refer to “Battery Negative Cable Disconnection and Connection: ”. 2.
Page 722 1E-9 Engine Lubrication System: Installation Procedure 3. Position the oil pan onto the block. 1. Install the 8 mm (0.315 in) guides from the EN 46109 into the center oil pan rail bolt hole on each side of the engine block. 4.
Page 723 Engine Lubrication System: 1E-10 Oil Pump Replacement Removal Procedure CAUTION Refer to “Fastener Notice: ”. NOTE 6. Tighten the oil pan bolts in sequence shown. Do not remove the left bank idler sprocket. Tightening torque 1. Remove the primary timing chain. Refer to “Primary 1.
Page 724 1E-11 Engine Lubrication System: Installation Procedure 4. Remove the oil suction pipe bolts. 1. Assemble the oil pump as necessary. Refer to “Oil 5. Remove the oil suction pipe. Pump Assemble”. 2. Install the oil pump. Refer to “Oil Pump Installation”. 3.
Page 725 Engine Lubrication System: 1E-12 Installation Procedure 4. Install the oil pan scraper. 1. Install a NEW oil suction tube seal onto the oil 5. Install the oil pan scraper bolts. suction tube. DO NOT reuse the old oil suction tube Tightening torque seal.
Page 726 1E-13 Engine Lubrication System: Oil Filter Adapter Removal Reference: “Exhaust Manifold Removal - Left Side: ”. 2. Remove the oil level indicator and tube by sliding the tube out from the lower crankcase hole. 1. Remove and properly dispose of the oil filter. 3.
Page 727: Oil Pan Removal
Engine Lubrication System: 1E-14 3. Remove the oil filter adapter. 6. Remove the left knock sensor. Reference: “Oil Filter Adapter Disassemble: ”. Oil Pan Removal Reference: “Cylinder Head Removal - Left Side: ”. Reference: “Cylinder Head Removal - Right Side: ”. 4.
Page 728 1E-15 Engine Lubrication System: Oil Pump Removal Reference: “Oil Pan Removal: ”. 2. Using the pry points located at the edge of the oil pan shear the RTV sealant. 1. Remove the oil pump bolts. 2. Remove the oil pump. Reference: “Oil Pump Disassemble: ”.
Page 729 Engine Lubrication System: 1E-16 2. Remove the primary camshaft drive chain lower 5. Remove the oil pump cover from the oil pump guide bolts. housing. 3. Remove the primary camshaft drive chain lower guide. 6. Remove the inner oil pump drive gear. 7.
Page 730 1E-17 Engine Lubrication System: NOTE There are no serviceable components within the oil pump. Disassemble the pump only to diagnose an oiling concern. A disassembled oil pump must not be reused. A disassembled oil pump must be replaced. 1. Inspect the oil pump housing for the following: –...
Page 731 Engine Lubrication System: 1E-18 3. Inspect the inner drive gear for damage. If inner 5. Inspect the oil pump relief valve components for diameter damage is found, ensure the crankshaft is debris or damage. also inspected. 6. Inspect the primary camshaft drive chain lower guide 4.
Page 732 1E-19 Engine Lubrication System: Oil Pump Assemble Reference: “Oil Pump Cleaning and Inspection: ”. 3. Install the inner and the outer rotors in the oil pump cover in the same orientation as removed. 1. Install the oil pressure relief valve components. 4.
Page 733 Engine Lubrication System: 1E-20 2. Remove the oil filter fitting. CAUTION Reference: “Oil Filter Adapter Cleaning and Inspection: Refer to “Fastener Notice: ”. ”. 6. Install the oil pump bolts. Oil Filter Adapter Cleaning and Inspection Reference: “Oil Filter Adapter Disassemble: ”. Tightening torque Tighten the oil pump bolts to 10 N⋅m (89 lb in).
Page 734 1E-21 Engine Lubrication System: NOTE Oil Filter Adapter Assemble Reference: “Oil Filter Adapter Cleaning and Inspection: The internal parts of the oil filter adapter ”. housing are not serviced separately. If wear or damage is noted, replace the entire oil filter adapter assembly.
Page 735 Engine Lubrication System: 1E-22 Oil Pan Disassemble Reference: “Oil Pan Removal: ”. 4. Remove the oil suction pipe bolts. 5. Remove the oil suction pipe. 1. Remove the oil pan drain plug. 6. Remove the oil suction tube seal from the oil suction 2.
Page 736 1E-23 Engine Lubrication System: Oil Pan Cleaning and Inspection Reference: “Oil Pan Disassemble: ”. Special tool J 28410 Gasket Remover Cleaning Procedure 1. Remove any old thread sealant, gasket material or sealant using J 28410. 2. Clean the oil pan and oil pan components in solvent. 3.
Page 737 Engine Lubrication System: 1E-24 1. Inspect the mounting surface (1) for possible leakage paths. 2. Inspect the oil pump pipe tube (2) for cracks, imperfections and/or damage. 3. Inspect the oil pump pipe support bracket (3) for cracks or damage. 4.
Page 738 1E-25 Engine Lubrication System: Oil Pump Installation 3. Install the oil suction pipe bolts. Reference: “Oil Pump Assemble: ”. Tightening torque Tighten the oil suction pipe bolts to 10 N⋅m (89 lb in). 1. Align the oil pump generator with the crankshaft flats and install the oil pump to the engine block.
Page 739: Oil Pan Installation
Engine Lubrication System: 1E-26 Oil Pan Installation Reference: “Oil Pan Assemble: ”. Special tool EN 46109 Guide Pin Set 3. Position the oil pan onto the block. 1. Install the 8 mm (0.315 in) guides from the EN 46109 into the center oil pan rail bolt hole on each side of the engine block.
Page 740 1E-27 Engine Lubrication System: CAUTION CAUTION Refer to “Fastener Notice: ”. Refer to “Fastener Notice: ”. 6. Tighten the oil pan bolts in sequence shown. 2. Install the knock sensor bolt. Tightening torque Tightening torque Tighten the knock sensor bolt to 23 N⋅m (17 lb ft). 1.
Page 741 Engine Lubrication System: 1E-28 5. Place the oil filter adapter into position. 7. Install a NEW oil filter. Reference: “Exhaust Manifold Installation - Left Side: ”. Oil Level Indicator and Tube Installation 6. Install the oil filter adapter bolts. Ensure the longer bolts (1) is installed in the upper rear position.
Page 742 1E-29 Engine Lubrication System: 2. Install the oil level indicator and tube by sliding the CAUTION tube down through the lower crankcase hole. Refer to “Fastener Notice: ”. 3. Install the oil level indicator tube bracket bolt. Tightening torque Tighten the oil level indicator tube bracket bolt to 10 N⋅m (89 lb in).
Page 743 Engine Lubrication System: 1E-30 Special Tools and Equipment Tools and Equipment Illustration Tool Number/Description • Special tools are listed and illustrated throughout this section, with a complete listing at the end of the section. These tools, or their equivalents, are designed to quickly and safely accomplish the operations for which they are intended.
Page 744: Engine Cooling System
1F-1 Engine Cooling System: Engine Cooling System General Description Cooling System Description and Operation Coolant Heater The optional engine coolant heater (RPO K05) operates Cooling Fan Control using 110-volt AC external power and is designed to The engine cooling fan system consists of 2 cooling fans warm the coolant in the engine block area for improved and 3 relays.
Page 745 Engine Cooling System: 1F-2 Coolant Surge Tank The engine coolant is a solution made up of a 50-50 The surge tank is a plastic tank that the pressure cap mixture of DEX-COOL and suitable drinking water. The mounts onto. The tank is mounted at a point higher than coolant solution carries excess heat away from the all other coolant passages.
Page 746 1F-3 Engine Cooling System: Transmission Oil Cooler When the coolant temperature is below the rated thermostat opening temperature, the thermostat valve The transmission oil cooler is a heat exchanger. It is remains closed. This prevents circulation of the coolant located inside the left side end tank of the radiator. The to the radiator and allows the engine to warm up.
Page 747 Engine Cooling System: 1F-4 Engine Cooling Schematics...
Page 748 1F-5 Engine Cooling System: Cooling System Connector End Views Cooling Fan - Right Cooling Fan - Left Connector Part Information OEM: 13517352 Connector Part Information Service: 88988506 OEM: 13517352 Description: 2-Way F GT 280 Sealed (BK) Service: 88988506 Terminal Part Information Description: 2-Way F GT 280 Sealed (BK) Terminal/Tray: 15304720/19 Terminal Part Information...
Page 749 Engine Cooling System: 1F-6 Component Location Cooling System Component Views Front of the Engine Compartment 1. Fuse Block - Underhood 3. Cooling Fan - Left 2. Battery 4. Cooling Fan - Right...
Page 750 1F-7 Engine Cooling System: Diagnostic Information and Procedures Diagnostic Starting Point - Engine Cooling Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Diagnostic System Check - Vehicle will provide the following information: • The identification of the control modules which command the system •...
Page 751 Engine Cooling System: 1F-8 Scan Tool Data List (3.6L) - Engine Cooling All: The Parameter is in all data lists indicated below. Eng: Engine Data The Engine Scan Tool Data List contains all cooling Ign: Ignition Data system related parameters that are available on the scan EVAP: EVAP Data tool.
Page 752 1F-9 Engine Cooling System: DTC P0480, P0481, P0691, P0692, P0693, or P0694 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 753 Engine Cooling System: 1F-10 Action Taken When the DTC Sets Circuit/System Verification DTCs P0480, P0481, P0691, P0692, P0693, and P0694 1. Ignition ON, command the appropriate fan relay ON are Type B DTCs. and OFF with a scan tool. You should hear or feel the relay click.
Page 754 1F-11 Engine Cooling System: Symptoms - Engine Cooling 3. Test for 2.6-4.6 volts between the relay coil control circuit terminal of both fan relays and ground. NOTE ➢ If less than the specified range, test the relay coil Review the system operation in order to control circuit for an open/high resistance or for a familiarize yourself with the system short to ground.
Page 755 Engine Cooling System: 1F-12 Cooling Fan Always On Cooling FAN 3 Relay Terminal Identification Cooling Fan Supply Diagnostic Instructions Control Voltage • Perform the “Diagnostic System Check - Vehicle B+ - Switch B+ - Coil Diagnostic Information: ” prior to using this diagnostic Front of Vehicle procedure.
Page 756 1F-13 Engine Cooling System: Component Testing Circuit/System Description The engine control module (ECM) commands the fans 1. Ignition OFF, disconnect the cooling fan relay. ON in either high speed or low speed, depending on 2. Test for 70-110 ohms of resistance between cooling requirements.
Page 757 Engine Cooling System: 1F-14 Reference Information 4. One at a time, connect a 30A fused jumper between the relay switch B+ circuit terminal 30 and the relay Schematic Reference switch supply circuit terminal 87 of the applicable fan “Engine Cooling Schematics” relay.
Page 758: Engine Overheating
1F-15 Engine Cooling System: Engine Overheating Step Action DEFINITION: Either of the following conditions indicate a probable engine overheat condition. • The engine temperature gage is in the red (overheat) zone and/or the engine temperature indicator is ON. • Hot engine coolant overflows from the coolant recovery reservoir and/or radiator cap onto the ground while the engine is running.
Page 759 Engine Cooling System: 1F-16 Step Action The probable cause of the engine overheat is combustion chamber gasses leaking into the cooling system. This condition is usually caused by the following: • A worn or damaged cylinder head gasket • A worn or damaged cylinder head •...
Page 760 1F-17 Engine Cooling System: Step Action With the engine idling, inspect the coolant recovery system. Does the coolant recovery system discharge coolant while the Go to Step 15 Go to Step 11 engine is idling? Visually inspect the hoses, pipes and hose clamps at the following locations: •...
Page 761 Engine Cooling System: 1F-18 Step Action 1. Remove the transmission oil cooler lines from the radiator. 2. Pressure test the cooling system. Refer to “Cooling System Leak Testing”. Go to Step 24 Go to Step 25 3. Inspect the transmission oil cooler for coolant. Is coolant present? 1.
Page 762 1F-19 Engine Cooling System: Engine Fails To Reach Normal Operating Temperature Step Action 1. Ensure that the cooling system is full. 2. Allow the engine to cool. 3. Start the engine. Go to Step 2 Go to Step 3 4. Turn the air conditioning system off. 5.
Page 763 Engine Cooling System: 1F-20 4. Test the pressure cap for the following conditions: – Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. – Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5.
Page 764 1F-21 Engine Cooling System: Repair Instructions Radiator Drain Cock Replacement Draining and Filling Cooling System (LY7 GE 47716 Fill) Special tool GE-47716 Vac N Fill Coolant Refill Tool Special tool • J 26568 Coolant and Battery Fluid Tester Removal Procedure •...
Page 765 Engine Cooling System: 1F-22 Vac-N-Fill Procedure WARNING To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
Page 766 1F-23 Engine Cooling System: 8. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank. 5. Attach the fill hose to the barb fitting on the vacuum gauge assembly. Ensure that the valve is closed.
Page 767 Engine Cooling System: 1F-24 11. Attach the vacuum hose to the vacuum gauge 13. Continue to draw vacuum until the needle stops assembly and the vacuum tank. rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
Page 768 1F-25 Engine Cooling System: 19. Once the vacuum gauge reaches zero, close the 26. Open the valve on the venturi assembly to start a valve on the vacuum gauge assembly and repeat vacuum draw. steps 12-18. 27. Use the extraction hose to draw out coolant to the 20.
Page 769 Engine Cooling System: 1F-26 Draining and Filling Cooling System (LY7 Static Fill) Draining Procedure WARNING In order to avoid personal injury, do not remove the cap or open the cooling system drains from a hot system. Allow the system to cool first. 3.
Page 770 1F-27 Engine Cooling System: 6. Add additional coolant to the surge tank until the Heater Inlet Pipe Replacement level is approximately 13 mm (0.5 in) above the Removal Procedure surge tank seam. 7. Install the coolant surge tank cap. Coolant System Flushing Flushing NOTE Do not use a chemical flush.
Page 771 Engine Cooling System: 1F-28 Installation Procedure Heater Outlet Pipe Replacement Removal Procedure 1. Install a NEW heater inlet pipe housing seal. 1. Partially drain the cooling system. Refer to “Draining CAUTION and Filling Cooling System (LY7 GE 47716 Fill)” Refer to “Fastener Notice: ”. “Draining and Filling Cooling System (LY7 Static Fill)”.
Page 772 1F-29 Engine Cooling System: Installation Procedure 1. Install a NEW heater inlet pipe O-ring. CAUTION Refer to “Fastener Notice: ”. 2. Install the heater outlet pipe (1). 3. Install the heater outlet hose (1) to the heater outlet pipe. 4. Install the heater inlet pipe. Refer to “Heater Inlet Pipe Replacement”.
Page 773 Engine Cooling System: 1F-30 Heater Outlet Hose Replacement Callout Component Name Preliminary Procedure 1. Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”. 2. Remove the heater outlet hose clamp from the heater core. 3.
Page 774 1F-31 Engine Cooling System: Radiator Surge Tank Inlet Hose/Pipe Replacement Callout Component Name Preliminary Procedure Partially drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”. Surge Tank Inlet Hose Clamps (Qty: 2) Surge Tank Inlet Hose...
Page 775 Engine Cooling System: 1F-32 Surge Tank Replacement Installation Procedure Special tool GE-47716 1617 Vac N Fill Coolant Refill Tool Removal Procedure 1. Drain the engine coolant. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”.
Page 776 1F-33 Engine Cooling System: Radiator Inlet Hose Replacement Callout Component Name Preliminary Procedure Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”. Radiator Inlet Hose Clamps Radiator Inlet Hose...
Page 777 Engine Cooling System: 1F-34 Radiator Outlet Hose Replacement Callout Component Name Preliminary Procedure 1. Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”. 2. Raise and suitably support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”. Radiator Outlet Hose Clamps Radiator Outlet Hose...
Page 778 1F-35 Engine Cooling System: Cooling Fan and Shroud Replacement Special tool GE-47716 1617 Vac N Fill Coolant Refill Tool Removal Procedure 8. Remove the CRFM mounting bracket bolts from the radiator support. 9. Remove the CRFM mounting brackets from the radiator support.
Page 779 Engine Cooling System: 1F-36 Installation Procedure 1. Install the fan assembly to the vehicle. 2. Return the condenser and radiator assembly to the mounted position. 12. Disconnect the transmission cooler lines from the radiator. 13. Unclip the transmission cooler lines from the fan assembly.
Page 780 1F-37 Engine Cooling System: 7. Clip the transmission cooler lines to the fan 12. Install the CRFM closeout panel to the condenser. assembly. 13. Install the CRFM closeout panel retainers to the 8. Connect the transmission cooler lines to the radiator. condenser.
Page 781 Engine Cooling System: 1F-38 Engine Coolant Fan Motor Replacement Special tool GE-47827 Socket NOTE Hold the fan blade to prevent rotation. 2. Using GE-47827 or equivalent, turn the fan motor This vehicle is equipped with counter-rotating engine drive plate in the opposite direction of the arrow cooling fans.
Page 782 1F-39 Engine Cooling System: NOTE Installation Procedure When reusing the fan motor(s) tape off the front and rear entry points of the fan motor(s) before drilling the rivets. Support the fan motor(s) and shroud prior to center punching the rivets. 4.
Page 783 Engine Cooling System: 1F-40 CAUTION Failure to heat the fan hub in hot tap water before installation will result in cooling fan failure due to cracking. Allowing the heated fan to cool for more than one minute prior to installation will also result in failure due to cracking.
Page 784 1F-41 Engine Cooling System: Radiator Replacement Callout Component Name Preliminary Procedure 1. Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” “Draining and Filling Cooling System (LY7 Static Fill)”. 2. Raise and suitably support the vehicle as necessary. Refer to “Lifting and Jacking the Vehicle: ”. 3.
Page 785 Engine Cooling System: 1F-42 Engine Coolant Thermostat Housing 1. Install the thermostat housing bolts. Replacement Tightening torque Removal Procedure Tighten the thermostat housing bolts to 10 N⋅m (89 lb in). 2. Install the heater inlet and outlet pipes. Refer to “Heater Inlet Pipe Replacement”...
Page 786 1F-43 Engine Cooling System: Installation Procedure 1. Remove the fuel injector sight shield. Refer to “Fuel Injector Sight Shield Replacement: ”. 2. Remove the surge tank inlet hose. Refer to “Radiator Surge Tank Inlet Hose/Pipe Replacement”. 3. Reposition the coolant air bleed hose clamp (1) at the coolant air bleed hose.
Page 787 Engine Cooling System: 1F-44 Water Outlet Housing Replacement 4. Install the radiator outlet hose. Refer to “Radiator Outlet Hose Replacement”. Removal Procedure Water Pump Replacement Special tool EN 46104 Water Pump Pulley Holding Tool Removal Procedure 1. Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)”...
Page 788 1F-45 Engine Cooling System: 6. Remove the water pump bolts. 4. Install the water pump pulley and the water pump pulley bolts. 7. Remove the water pump. 8. Remove and DISCARD the water pump seal. 9. Carefully clean the water pump sealing surfaces. Installation Procedure 5.
Page 789 Engine Cooling System: 1F-46 Coolant Heater Replacement 4. Refill the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)” Removal Procedure “Draining and Filling Cooling System (LY7 Static 1. Turn the ignition OFF. Fill)”. 2. Drain the cooling system. Refer to “Draining and Filling Cooling System (LY7 GE 47716 Fill)”...
Page 790 1F-47 Engine Cooling System: Installation Procedure Water Outlet Removal Reference: “Exhaust Manifold Removal - Right Side: ”. 1. Position the coolant heater power supply cord to the fender panel and air cleaner assembly. 1. Disconnect the engine coolant air bleed hose (1) from the water outlet.
Page 791 Engine Cooling System: 1F-48 Engine Coolant Thermostat Housing Removal Reference: “Water Outlet Removal: ”. 3. Remove the water outlet. 1. Remove the heater inlet/outlet pipe assembly bolts. 4. Remove and discard the water outlet gasket and O- ring. 2. Remove the heater inlet/outlet pipe assembly.
Page 792 1F-49 Engine Cooling System: 3. Remove and discard the heater inlet/outlet pipe 6. Remove and discard the coolant pipe O-ring. gasket and O-ring. 7. Remove the thermostat housing bolts. 4. Remove the coolant pipe bolt. 8. Remove the thermostat housing. 5.
Page 793 Engine Cooling System: 1F-50 9. Remove and discard the thermostat housing gasket. 2. Remove the water pump pulley bolts. 3. Remove the water pump pulley. Water Pump Removal Reference: “Camshaft Cover Removal - Right Side: ”. Special tool EN 46104 Water Pump Pulley Holding Tool 4.
Page 794 1F-51 Engine Cooling System: Water Pump Cleaning and Inspection Reference: “Water Pump Removal: ”. Cleaning Procedure CAUTION Do not immerse the water pump in solvent. The solvent may enter the water pump's permanently lubricated bearings and cause premature bearing failure. 1.
Page 795 Engine Cooling System: 1F-52 Water Pump Installation Reference: “Water Pump Cleaning and Inspection: ”. Special tool EN 46104 Water Pump Pulley Holding Tool 7. Install the EN 46104 (1) onto the water pump pulley. Tightening torque Tighten the water pump pulley bolts to 10 N⋅m (89 lb in).
Page 796 1F-53 Engine Cooling System: 2. Install the thermostat housing. 4. Install a NEW O-ring onto the coolant pipe. 5. Install the coolant pipe. CAUTION Refer to “Fastener Notice: ”. 3. Install the thermostat housing bolts. Ensure to install the short bolts (1) and the long bolt (2) in the proper position.
Page 797 Engine Cooling System: 1F-54 6. Install the coolant pipe bolt. 8. Install the heater inlet/outlet pipe assembly. Tightening torque Tighten the coolant pipe bolt to 10 N⋅m (89 lb in). 9. Install the heater inlet/outlet pipe assembly bolts. Tightening torque 7.
Page 798 1F-55 Engine Cooling System: Water Outlet Installation CAUTION 1. Install a NEW gasket and O-ring onto the water Refer to “Fastener Notice: ”. outlet. 3. Install the water outlet bolts. Tightening torque Tighten the water outlet bolts to 10 N⋅m (89 lb in). 2.
Page 799 Engine Cooling System: 1F-56 Specifications Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7) Specification Application Metric English Coolant Pipe Bolt 10 N⋅m 89 lb in Engine Coolant Air Bleed Pipe Bracket Bolt 10 N⋅m 89 lb in Heater Inlet/Outlet Pipe Assembly Bolt 10 N⋅m 89 lb in Thermostat Housing Bolt...
Page 800 1F-57 Engine Cooling System: Special Tools - Engine Mechanical - 3.6L Tool Number / Illustration (LY7) Description Illustration Tool Number/Description J 24460-01 Cooling System Pressure EN 46104 Tester Water Pump Pulley Holding Tool Special Tools - Engine Cooling Tool Number / Illustration J 24731 Description...
Page 801 Fuel System: 1G-1 Fuel System Precautions Fuel Pipe Fitting Caution WARNING Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak.
Page 802: Fuel System Description
1G-2 Fuel System: General Description Fuel System Description Fuel Fill Pipe Fuel System Overview This vehicle utilizes a returnless design Fuel System. The fuel pressure regulator is a part of the primary fuel tank module, eliminating the need for a return pipe from the engine.
Page 803 Fuel System: 1G-3 Secondary Fuel Tank Module CAUTION If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system.
Page 804 1G-4 Fuel System: Primary and Secondary Jet Pumps Fuel stoppage at the strainer indicates that the fuel tank contains an abnormal amount of sediment or water. Therefore, the fuel tank will need to be removed and cleaned, and the filter strainer should be replaced. Fuel Filter The primary jet pump (1) is located in the primary fuel tank module.
Page 805 Fuel System: 1G-5 On-Board Refueling Vapor Recovery (ORVR) EVAP Lines and Hoses System The EVAP line extends from the fuel tank vent valve to the EVAP canister and into the engine compartment. The on-board refueling vapor recovery (ORVR) system The EVAP line is made of nylon and connects to the is an on-board vehicle system to recover fuel vapors EVAP canister with a quick connect fitting.
Page 806 1G-6 Fuel System: Fuel Pump Relay Sequential Fuel Injection (SFI) The fuel pump relay allows the ECM to energize the fuel The ECM controls the fuel injectors based on information pump. The ECM enables the fuel pump whenever the that the ECM receives from several information sensors. crankshaft position (CKP) sensor pulses are detected.
Page 807: Front Brakes
Fuel System: 1G-7 Battery Voltage Correction Mode The ECM can compensate in order to maintain acceptable vehicle driveability when the ECM sees a low battery voltage condition. The ECM compensates by performing the following functions: • Increasing the injector pulse width in order to maintain the proper amount of fuel being delivered •...
Page 808 1G-8 Fuel System: Diagnostic Information and Procedures Diagnostic Starting Point - Engine Controls Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Diagnostic System Check - Vehicle will provide the following information: • The identification of the control modules which command the system •...
Page 809 Fuel System: 1G-9 Scan Tool Output Additional Menu Description Control Selection(s) NOTE The EVAP Purge Solenoid Command parameter may not change states when using this output control. Special Functions/ This function controls the evaporative emission (EVAP) purge Engine Control Module/ solenoid valve.
Page 810 1G-10 Fuel System: Scan Tool Output Additional Menu Description Control Selection(s) Special Functions/ This function resets the fuel trim data and the learned values for the Fuel Trim Reset Engine Control module/ rear heated oxygen sensors. Fuel System This function allows the throttle position and the idle speed to be relearned by the ECM, once the following conditions have been Special Functions// met.
Page 811 Fuel System: 1G-11 ET: Electrical/Theft Data Only the parameters listed below are referenced in this service information for use in diagnosis. If all values are EVAP: EVAP Data within the typical range described below, refer to FF: Freeze Frame Data “Symptoms - Engine Controls: ”.
Page 812 1G-12 Fuel System: Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off Cruise Disengage 1-8 Reason Varies History Cruise Inhibited Yes/No Cruise On/Off Switch On/Off Cruise Resume/Accel. ON/OFF Switch Cruise Set/Coast Switch ON/OFF Cylinder 1-6 IC Circuit...
Page 813 Fuel System: 1G-13 Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off EVAP Vent Solenoid Circuit EVAP OK/Fault/Indeterminate Status EVAP Vent Solenoid Eng, EVAP, FT Venting/Not Venting Venting Command Exh.
Page 814 1G-14 Fuel System: Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off Ignition 1 Signal Eng, ET, EVAP On/Off IMRC Solenoid Circuit OK/Fault/Indeterminate Status IMRC Solenoid Command On/Off Initial Brake Apply Signal CT, Eng, ET, IM, TAC, Trans Applied/Released Released...
Page 815 Fuel System: 1G-15 Scan Tool Parameter Data List Parameter Range/Units Typical Data Values Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop/Accessories Off −39° to +140°C (−38° to Start Up ECT CH, EVAP, HO2S, IM Varies +284°F) −39° to +140°C (−38° to Start Up IAT CH, EVAP, HO2S, IM Varies...
Page 816 1G-16 Fuel System: Scan Tool Data Definitions - Engine Air Fuel Ratio: This parameter displays the ratio of air to fuel as calculated by the control module based on Controls - 3.6L (LY7) various sensor inputs. The scan tool will display a The Scan Tool Data Definitions list contains a brief lower air fuel ratio when a richer air to fuel mixture is description of all of the engine related parameters that...
Page 817 Fuel System: 1G-17 Cylinder 1-6 Injector Circuit Status: This parameter Calc. TWC Temp. Bank 1 or Bank 2: This parameter displays the catalytic converter temperature as displays the state of the fuel injector control circuit. calculated by the control module. The parameter displays Fault if the fuel injector Catalytic Converter Protection Active: This control circuit is open, shorted to ground, or shorted...
Page 818 1G-18 Fuel System: EVAP Vent Solenoid Command: This parameter Engine Off EVAP Test Conditions Met: This parameter displays Yes if the conditions for running displays the state of the control circuit for the Engine Off EVAP diagnostic are met. evaporative emission (EVAP) vent solenoid as Engine Off Time: This parameter displays the amount commanded by the control module.
Page 819 Fuel System: 1G-19 HO2S Bank 1 or 2 Sensor 1 or 2 Heater Command: Fuel Tank Level Remaining: This parameter displays the amount of fuel in liters/gallons that remains in the This parameter displays the commanded state of the fuel tank as determined by the control module from Bank 2 Sensor 1 heater by the control module.
Page 820 1G-20 Fuel System: Loop Status Bn. 1 or 2 Sen. 1: This parameter Injector 1-6 Command: This parameter displays the amount of fuel injector ON time or pulse width as displays the state of the fuel control system as commanded by the control module. commanded by the control module.
Page 821 Fuel System: 1G-21 Misfire Current Cyl. 1-6: The scan tool displays a Start Up ECT: This parameter displays the temperature range of 0-200 counts. This parameter displays the of the engine coolant on start up based on input to number of misfires that have been detected during the control module from the ECT sensor.
Page 822 1G-22 Fuel System: VTD Auto. Learn Timer: This parameter indicates that Total Fuel Trim Avg. Bank 1 or Bank 2: This parameter displays the overall fuel trim from the idle/ either the auto learn timer (used in the auto learn decel cell and the cruise/accel cell.
Page 823 Fuel System: 1G-23 Diagnostic Aids ➢ If the fuel pump fuse is open, test for a short to ground in the supply voltage circuit of the fuel The following conditions may cause the fuel pump fuse pump. If the circuit/connections test normal, replace to open: the fuel pump.
Page 824 1G-24 Fuel System: Fuel System Diagnosis • A vehicle that runs out of fuel above empty may be caused by an inaccurate fuel level sender. Inspect the Diagnostic Instructions float arm for binding, or obstructions. • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ”...
Page 825 Fuel System: 1G-25 Circuit/System Testing 4. Remove the J 37287 and J 34730-1A. Refer to “Fuel Pressure Gage Installation and Removal”. 1. Ignition ON, command the fuel pump relay ON with a 5. Operate the vehicle within the conditions of the scan tool and observe the fuel pressure while the customer concern while monitoring fuel related fuel pump is operating.
Page 826 1G-26 Fuel System: Diagnostic Aids Component Testing Verify the resistance of each fuel injector with one of the • Monitoring the misfire current counters, or misfire following methods: graph, may help to isolate the fuel injector that is causing the condition. •...
Page 827 Fuel System: 1G-27 Circuit/System Description 4. Monitor the fuel pressure gage for 1 minute. Verify that the fuel pressure does not drop more than 34 The scan tool is first used to energize the fuel pump kPa (5 psi). relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a ➢...
Page 828 1G-28 Fuel System: Fuel Injector Balance Test with Tech 2 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. •...
Page 829 Fuel System: 1G-29 Fuel Tank Leak Test 5. With a scan tool, select the Fuel Injector Balance Test function, within the Special Functions menu. Diagnostic Instructions Select a fuel injector to be tested and press Enter in • Perform the “Diagnostic System Check - Vehicle order to prime the fuel system.
Page 830 1G-30 Fuel System: Circuit/System Verification Alcohol/Contaminants-in-Fuel Diagnosis (w/o Special Tool) WARNING Diagnostic Instructions Place a dry chemical (Class B) fire • Perform the “Diagnostic System Check - Vehicle extinguisher near the area before performing Diagnostic Information: ” prior to using this diagnostic a Fuel Tank Leak Check.
Page 831 Fuel System: 1G-31 Particulate Contaminants in Fuel Testing If alcohol is present in the fuel, the volume of the lower layer, that now contains both alcohol and water, will be Procedure more than 10 ml (0.37 oz). For example, if the volume of The fuel sample should be drawn from the bottom of the the lower layer is increased to 15 ml (0.51 oz), this tank so that any contaminants present in the tank will be...
Page 832 1G-32 Fuel System: Repair Instructions Fuel Pressure Relief (With J 34730-1A) 3. Remove the fuel rail service port cap. Special tool WARNING J 34730-1A Fuel Pressure Gage Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire WARNING and personal injury.
Page 833 Fuel System: 1G-33 Fuel Pressure Relief (Without J 34730-1A) Fuel Pressure Gage Installation and Removal WARNING Special tool Refer to “Gasoline/Gasoline Vapors Caution: J 34730-1A Fuel Pressure Gage ”. Installation Procedure WARNING WARNING Remove the fuel tank cap and relieve the fuel Refer to “Gasoline/Gasoline Vapors Caution: system pressure before servicing the fuel ”.
Page 834 1G-34 Fuel System: Removal Procedure 2. Disconnect the J 34730-1A from the fuel rail service port. 3. Install the fuel rail service port cap. 4. Tighten the fuel fill cap. Metal Collar Quick Connect Fitting Service Special tool J 37088-A Fuel Line Disconnect Tool Set Removal Procedure WARNING Refer to “Gasoline/Gasoline Vapors Caution:...
Page 835 Fuel System: 1G-35 WARNING WARNING Refer to “Fuel and Evaporative Emission Refer to “Relieving Fuel Pressure Caution”. Hose/Pipe Connection Cleaning Notice: ”. 5. Pull the connection apart. 6. Use a clean shop towel in order to wipe off the male WARNING pipe end.
Page 836 1G-36 Fuel System: Plastic Collar Quick Connect Fitting Service Removal Procedure WARNING Refer to “Gasoline/Gasoline Vapors Caution: ”. 2. Push both sides of the fitting together in order to snap the retaining tabs into place. NOTE There are several types of plastic collar fuel and evaporative emission quick connect fittings used on this vehicle.
Page 837 Fuel System: 1G-37 4. This step applies to Q Release style connectors WARNING ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. Refer to “Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice: ”. WARNING Refer to “Safety Glasses Caution: ”.
Page 838 1G-38 Fuel System: Installation Procedure 6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of WARNING the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the Refer to “Fuel Pipe Fitting Caution”.
Page 839 Fuel System: 1G-39 3. Once installed, pull on both sides of the quick- 1. Disconnect the negative battery cable. Refer to connect fitting in order to make sure the connection “Battery Negative Cable Disconnection and is secure. Connection: ”. 2. Disconnect the fuel feed pipe quick connect fitting (3) Fuel Feed Pipe Replacement from the fuel rail.
Page 840 1G-40 Fuel System: 8. Disconnect the fuel feed pipe quick connect fitting (2) 11. Disconnect the right rear brake line fitting from the from the fuel tank. Refer to “Plastic Collar Quick rear brake hose. Connect Fitting Service”. 9. Cap the fuel and EVAP lines in order to prevent system contamination.
Page 841 Fuel System: 1G-41 15. Remove the fuel feed pipe from the fuel/EVAP/brake 2. With the aid of an assistant, position and install the pipe assembly clips. fuel/EVAP/brake pipe clips (2) to the underbody studs. Installation Procedure 3. Install the push pin (1) to the underbody side rail hole.
Page 842 1G-42 Fuel System: 5. Connect the left rear brake line fitting to the brake 10. Connect the rear brake line fittings to the brake crossover pipe. pressure module. Tightening torque Tightening torque Tighten the fitting to 18 N⋅m (13 lb ft). Tighten the fitting to 21 N⋅m (16 lb ft).
Page 843 Fuel System: 1G-43 16. Prime the fuel system. a. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat cycling twice. b. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. c.
Page 844 1G-44 Fuel System: Installation Procedure 7. Disconnect the fuel injector electrical connector. 1. Install NEW fuel injector seals. 2. Install the fuel injector. 8. Remove the fuel injector retainer clip. 3. Install the fuel injector retainer clip. 9. Remove the fuel injector. 10.
Page 845 Fuel System: 1G-45 4. Install the fuel injector electrical connector. Fuel Tank Draining 5. Engage the fuel injector electrical connector lock. Special tool J 34730-262 Fuel Pressure/Test Gage Adapter J 42960-2 Fuel Flapper Door Holder J 45004 Fuel Tank Drain Hose For any operation requiring removal of the fuel tank, there should be no more than 11.4 L (3 gal) of fuel remaining.
Page 846 1G-46 Fuel System: 2. Disconnect the fuel feed line quick connect fitting at the fuel rail. Refer to “Metal Collar Quick Connect Fitting Service”. 3. Install the 3/8 x 1/4 in quick connect fitting from the J 34730-262 into the fuel feed line. 4.
Page 847 Fuel System: 1G-47 3. Insert the J 42960-2 into the fuel fill pipe. WARNING NOTE Do not allow smoking or the use of open The siphon hose will reach the bottom of the flames in the area where work on the fuel or tank, on the primary side only, within about EVAP system is taking place.
Page 848 1G-48 Fuel System: Filler Tube Replacement Removal Procedure NOTE Replacement fuel filler tube hoses do not come equipped with hose clamps. Obtain replacement hose clamps prior to beginning this service procedure. WARNING Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place.
Page 849 Fuel System: 1G-49 11. Separate the fuel tank fill vent hose from the fuel fill 2. Install the closeout grommet. tube. Installation Procedure 3. Position the fuel fill tube (1) to the vehicle. 1. Attach the fuel tank fill vent hose to the fuel fill tube.
Page 850 1G-50 Fuel System: 6. Position the fill tube-to-fuel tank connecting hose and hose clamp. Tightening torque Tighten the clamp to 5 N⋅m (44 lb in). 7. Connect the fuel fill vent tube and fresh air hose. 8. Install the inner wheelhouse liner. Refer to “Rear Wheelhouse Liner Panel Replacement: ”.
Page 851 Fuel System: 1G-51 1. Relieve the fuel system pressure. Refer to “Fuel Pressure Relief (With J 34730-1A)” “Fuel Pressure Relief (Without J 34730-1A)”. 2. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level.
Page 852 1G-52 Fuel System: Installation Procedure 6. Connect the fuel fill tube to the fuel tank. 1. If previously removed, install the fuel tank module Tightening torque assemblies. Refer to “Primary Fuel Tank Module Tighten the clamp to 5 N⋅m (44 lb in). Replacement”...
Page 853 Fuel System: 1G-53 Fuel Tank Replacement (AWD) 5. Remove the propeller shaft. Refer to “Propeller Shaft Replacement: ”Propeller Shaft Replacement. Removal Procedure 6. Disconnect the evaporative emission (EVAP) WARNING canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to “Plastic Collar Quick Do not allow smoking or the use of open Connect Fitting Service”.
Page 854 1G-54 Fuel System: 2. Install the fuel tank heat shield and fuel tank assembly to the vehicle. CAUTION Refer to “Fastener Notice: ” in Cautions and Notices. 3. Install the fuel tank straps and the fuel tank strap-to- body bolts. Tightening torque Tighten the bolts to 25 N⋅m (18 lb ft).
Page 855 Fuel System: 1G-55 Fuel Tank Pressure Sensor Replacement Removal Procedure 7. Connect the chassis fuel feed line quick connect fitting to the fuel tank. Refer to “Plastic Collar Quick Connect Fitting Service”. 1. Remove the fuel tank. Refer to “Fuel Tank 8.
Page 856 1G-56 Fuel System: Installation Procedure Primary Fuel Tank Module Replacement Special tool J 45722 Fuel Sender Lock Ring Wrench Removal Procedure NOTE NEW fuel tank module seals are necessary each time the fuel tank module is serviced. Obtain NEW seals for both the primary and secondary modules prior to beginning this service procedure.
Page 857 Fuel System: 1G-57 5. Remove the primary fuel pump module assembly. NOTE Always replace the fuel pump module-to-tank seal, O-ring, when the fuel pump module is removed. 6. Discard the fuel pump module-to-tank seal. 7. If the fuel level sending unit is being replaced, remove the fuel level sender.
Page 858 1G-58 Fuel System: Installation Procedure 4. Connect the wiring harness to the primary fuel pump module and fuel tank pressure sensor. 5. Install the fuel tank. Refer to “Fuel Tank Replacement (FWD)” “Fuel Tank Replacement (AWD)”. Secondary Fuel Tank Module Replacement Special tool J39765-A Fuel Sender Lock Ring Tool Removal Procedure...
Page 859 Fuel System: 1G-59 Installation Procedure CAUTION 1. If the fuel level sending unit is being replaced, install To prevent retainer damage, do not attempt to the fuel level sending unit into the new fuel pump. remove the retainer with a 12 in. or shorter Refer to “Fuel Level Sensor Replacement - ratchet/breaker bar.
Page 860 1G-60 Fuel System: Primary Fuel Level Sensor Replacement Installation Procedure Removal Procedure NOTE NEW fuel tank module seals are necessary each time the fuel tank module is serviced. Obtain NEW seals for both the primary and secondary modules prior to beginning this service procedure.
Page 861 Fuel System: 1G-61 NOTE Fuel Tank Filler Vent Hose Replacement Removal Procedure There are 2 fuel level sender unit and float assemblies in the fuel tank. There is 1 located on each fuel pump module. The fuel level sender unit and float is NOT the same for each of the fuel pump modules.
Page 862 1G-62 Fuel System: Fuel System Cleaning NOTE When flushing the fuel tank, handle the fuel NOTE and water mixture as a hazardous material. Only use oil free compressed air to blow out Handle the fuel and water in accordance with fuel pipes.
Page 863 Fuel System: 1G-63 Special Tools and Equipment Special Tools - Engine Controls - 3.6L (LY7) Illustration Tool Number/Description Illustration Tool Number/Description J 37088-A Fuel Line Disconnect Tool EL 39021-460 Fuel Injector Test Adapter J 37287 Fuel Line Shut-Off GE 41415-50 Adapters Interrupted Thread Fuel Tank Cap Adapter...
Page 864 1G-64 Fuel System: Illustration Tool Number/Description Illustration Tool Number/Description J 39765-A J 44602 Fuel Sender Lock Ring Injector Test Adapter Tool J 41413-200 J 45004 Evaporative Emission Fuel Tank Drain Hose System Tester (EEST) J 45722 J 42960-02 Fuel Sender Lock Ring Fuel Flapper Door Holder Wrench J 43244...
Page 865: Ignition System
Ignition System: 1H-1 Ignition System General Description Electronic Ignition (EI) System Description Camshaft Position (CMP) Sensor This engine uses 4 camshaft position (CMP) sensors, The electronic ignition (EI) system produces and one for each camshaft. The CMP sensor signals are a controls a high-energy secondary spark.
Page 866 1H-2 Ignition System: Diagnostic Information and Procedures Electronic Ignition (EI) System Diagnosis Special Tools Required Diagnostic Instructions • J 26792 Spark Tester • J 43244 Relay Puller Pliers • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic Circuit/System Testing procedure.
Page 867 Ignition System: 1H-3 Repair Instructions Ignition Coil Replacement - Bank 1 Installation Procedure Removal Procedure 1. Install the ignition coil(s). 1. Remove the fuel injector sight shield. Refer to “Fuel CAUTION Injector Sight Shield Replacement: ”. Refer to “Fastener Notice: ”. 2.
Page 868 1H-4 Ignition System: Ignition Coil Replacement - Bank 2 Installation Procedure Removal Procedure 1. Install the ignition coil(s). 1. Remove the air cleaner outlet duct. Refer to “Air CAUTION Cleaner Outlet Duct Replacement: ”. Refer to “Fastener Notice: ”. 2. Disconnect the engine wiring harness electrical connector(s) (5) from the ignition coil(s).
Page 869 Ignition System: 1H-5 Spark Plug Replacement Installation Procedure Removal Procedure CAUTION 1. Remove the ignition coil(s). Refer to “Ignition Coil Use only the spark plugs specified for use in Replacement - Bank 1” and/or “Ignition Coil the vehicle. Do not install spark plugs that Replacement - Bank 2”.
Page 870: Spark Plug Inspection
1H-6 Ignition System: 2. Install the spark plug. Tightening torque Tighten the spark plug to 20 N⋅m (15 lb ft). 3. Install the ignition coil(s). Refer to “Ignition Coil Replacement - Bank 1” and/or “Ignition Coil Replacement - Bank 2”. Spark Plug Inspection Spark Plug Usage •...
Page 871 Ignition System: 1H-7 Spark Plug Visual Inspection • Normal operation—Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. • Carbon fouled—Dry, fluffy, black carbon or soot caused by the following conditions: –...
Page 872 1H-8 Ignition System: Specifications Fastener Tightening Specifications - Engine Controls - 3.6L (LY7) Specification Application Metric English Ignition Coil Bolt 10 N⋅m 89 lb in Rear Drive Module Propeller Shaft Guard Bolt 25 N⋅m 18 lb ft Spark Plug 20 N⋅m 15 lb ft Ignition System Specifications Specification...
Page 873: Starting System
Starting System: 1I-1 Starting System General Description Starting System Description and Operation The starter motors are non-repairable starter motors. They have pole pieces that are arranged around the armature. Both solenoid windings are energized. The pull-in winding circuit is completed to the ground through the starter motor. The windings work together magnetically to pull and hold in the plunger.
Page 874 1I-2 Starting System: Starting...
Page 875 Starting System: 1I-3 Charging...
Page 876 1I-4 Starting System: Engine Electrical Connector End Views Generator Battery Current Sensor Connector Part Information OEM: 12186308 Connector Part Information Service: 89046837 OEM: 13519047 Description: 2-Way F JPT, Sealed (BK) Service: — Terminal Part Information Description: 3-Way F GT 150 Sealed (BK) Terminal/Tray: 4-964286-1/16 Terminal Part Information Core/Insulation Crimp: E/1...
Page 877 Starting System: 1I-5 Component Location Engine Electrical Component Views Front of the Engine Compartment 1. Fuse Block - Underhood 3. Cooling Fan - Left 2. Battery 4. Cooling Fan - Right...
Page 878 1I-6 Starting System: Bottom Front of the Engine 1. Generator 3. A/C Refrigerant Pressure Sensor 2. Starter 4. A/C Compressor Clutch...
Page 879 Starting System: 1I-7 LF of the Engine Compartment 1. LF Strut Tower 3. Windshield Washer Fluid Pump 2. G103 4. Battery Current Sensor...
Page 880 1I-8 Starting System: Diagnostic Information and Procedures Diagnostic Starting Point - Engine Electrical Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Diagnostic System Check - Vehicle will provide the following information: • The identification of the control modules which command the system •...
Page 881 Starting System: 1I-9 Digital Radio Receiver (DRR) Scan Tool Parameter Data List Units Displayed Typical Data Value Ignition ON/Engine Running Battery Voltage Data Display Volts 13.9 Volts Engine Control Module (ECM) Scan Tool Parameter Data List Units Displayed Typical Data Value Ignition ON/Engine OFF Crank Request Signal Electrical/Theft Data...
Page 882 1I-10 Starting System: Scan Tool Data Definitions - Engine DTC P0615 Electrical Circuit Description Battery Voltage: The scan tool displays 0-20 Volts. The The engine control module (ECM) supplies 12 volts to scan tool displays the voltage as received by the the control circuit of the crank relay when start enable Module.
Page 883 Starting System: 1I-11 Test Description This step tests the ground circuit of the crank relay. The numbers below refer to the step numbers on the This step verifies that the ECM is providing 12 volts to diagnostic table. the control circuit of crank relay. Listen for an audible click when the crank relay operates.
Page 884 1I-12 Starting System: DTC P0616 Conditions for Setting the DTC Circuit Description • The ECM detects an improper voltage level on the The engine control module (ECM) supplies 12 volts for output circuit that controls the starter relay. the starter relay when start enable has been requested. •...
Page 885 Starting System: 1I-13 DTC P0617 Conditions for Setting the DTC Circuit Description • The ECM detects an improper voltage level on the output circuit that controls the starter relay. The engine control module (ECM) supplies 12 volts for the starter relay when start enable has been requested. •...
Page 886 1I-14 Starting System: Symptoms - Engine Electrical Visual/Physical Inspection • Inspect for aftermarket devices which could affect the NOTE operation of the starting and charging systems. Refer The following steps must be completed to “Checking Aftermarket Accessories: ”. before using the symptom tables. •...
Page 887 Starting System: 1I-15 Step Action 1. Turn OFF the ignition. 2. Remove the crank relay. 3. Turn ON the ignition, with the engine OFF. Go to Step 7 Go to Step 15 4. Connect a test lamp between the control circuit of the crank relay coil and a good ground.
Page 888 1I-16 Starting System: Step Action Replace the crank relay. Go to Step 22 — Did you complete the replacement? Replace the starter motor. Refer to “Starter Motor Replacement”. Go to Step 22 — Did you complete the replacement? Replace the ECM. Refer to “Control Module References: ” for replacement, setup, and programming.
Page 889 Starting System: 1I-17 Starter Motor Noise Diagnosis Diagnostic Aids Inspect the flywheel ring gear for damage or unusual wear. Test Description The number below refers to the step number on the diagnostic table. A starter motor that remains engaged after engine start up can be cause by a starter relay that hangs up or a low current short to B+ on the starter solenoid crank voltage circuit.
Page 890 1I-18 Starting System: Repair Instructions Starter Motor Replacement Removal Procedure 6. Remove the starter bolts and starter. Installation Procedure 1. Disconnect the negative battery cable. Refer to “Battery Negative Cable Disconnection and Connection: ”. 2. Raise the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
Page 891 Starting System: 1I-19 Starter Removal Reference: “Drive Belt Tensioner Removal: ”. 3. Connect the engine harness electrical connector to the starter. 1. Remove the starter motor bolts. 4. Install the starter solenoid BAT terminal nut. 2. Remove the starter motor. Tightening torque Tighten the bolts/nuts to 13 N⋅m (115 lb in).
Page 892 1I-20 Starting System: Starter Installation 1. Install the starter motor. CAUTION Refer to “Fastener Notice: ”. 2. Install the starter motor bolts. Tightening torque Tighten the starter motor bolts to 50 N⋅m (37 lb ft). Reference: “Drive Belt Tensioner Installation: ”.
Page 893 Starting System: 1I-21 Specifications Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7) Specification Application Metric English Starter Motor Bolt 50 N⋅m 37 lb ft Fastener Tightening Specifications - Engine Electrical Specification Application Metric English Starter Solenoid Positive Battery Terminal Nut 10 N⋅m 89 lb in Starter Solenoid S Terminal Nut...
Page 894 1J-1 Charging System: Charging System Precautions Battery Disconnect Caution WARNING Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable.
Page 895 Charging System: 1J-2 General Description Battery Description and Operation WARNING Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: •...
Page 896 1J-3 Charging System: The battery specification label, example below, contains information about the following: • The test ratings • The original equipment catalog number • The recommended replacement model number Battery Ratings Charging System Description and A battery may have 3 ratings: Operation •...
Page 897 Charging System: 1J-4 In addition, the EPM function is designed to perform Engine Control Module (ECM) regulated voltage control (RVC) to improve battery SOC, The ECM directly controls the generator field control battery life, and fuel economy. This is accomplished by circuit input to the generator.
Page 898 1J-5 Charging System: Battery Sulfation Mode Start Up Mode The BCM will enter this mode when the interpreted When the engine is started the BCM sets a targeted generator output voltage is less than 13.2 volts for 45 generator output voltage of 14.5 volts for 30 seconds. minutes.When this condition exists the BCM will enter Charge Mode for 2-3 minutes.
Page 899 Charging System: 1J-6 Electrical Power Management Description and Operation Electrical Power Management The electrical power management (EPM) is used to monitor and control the charging system and alert the driver of possible problems within the charging system. The EPM system makes the most efficient use of the generator output, improves the battery state of charge (SOC), extends battery life.
Page 900 1J-7 Charging System: Starting...
Page 901 Charging System: 1J-8 Charging...
Page 902 1J-9 Charging System: Engine Electrical Connector End Views Generator Battery Current Sensor Connector Part Information OEM: 12186308 Connector Part Information Service: 89046837 OEM: 13519047 Description: 2-Way F JPT, Sealed (BK) Service: — Terminal Part Information Description: 3-Way F GT 150 Sealed (BK) Terminal/Tray: 4-964286-1/16 Terminal Part Information Core/Insulation Crimp: E/1...
Page 903 Charging System: 1J-10 Component Location Engine Electrical Component Views Front of the Engine Compartment 1. Fuse Block - Underhood 3. Cooling Fan - Left 2. Battery 4. Cooling Fan - Right...
Page 904 1J-11 Charging System: Bottom Front of the Engine 1. Generator 3. A/C Refrigerant Pressure Sensor 2. Starter 4. A/C Compressor Clutch...
Page 905 Charging System: 1J-12 LF of the Engine Compartment 1. LF Strut Tower 3. Windshield Washer Fluid Pump 2. G103 4. Battery Current Sensor...
Page 906 1J-13 Charging System: Diagnostic Information and Procedures Diagnostic Starting Point - Engine Electrical Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information: ”. The Diagnostic System Check - Vehicle will provide the following information: • The identification of the control modules which command the system •...
Page 907 Charging System: 1J-14 Digital Radio Receiver (DRR) Scan Tool Parameter Data List Units Displayed Typical Data Value Ignition ON/Engine Running Battery Voltage Data Display Volts 13.9 Volts Engine Control Module (ECM) Scan Tool Parameter Data List Units Displayed Typical Data Value Ignition ON/Engine OFF Crank Request Signal Electrical/Theft Data...
Page 908 1J-15 Charging System: Scan Tool Data Definitions - Engine DTC B1325 Electrical Circuit Description Battery Voltage: The scan tool displays 0-20 Volts. The The control modules on this vehicle monitor the battery scan tool displays the voltage as received by the voltage through the battery positive voltage circuits.
Page 909 Charging System: 1J-16 Step Action Values Schematic Reference:“Control Module References: ” Did you perform the Diagnostic System Check - Go to Vehicle? “Diagnostic System Check - — Go to Step 2 Vehicle Diagnostic Information: ” 1. Install a scan tool. 2.
Page 910 1J-17 Charging System: DTC B1405 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. • “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic category.
Page 911 Charging System: 1J-18 Circuit/System Testing Conditions for Running the DTC The ignition must be ON for this code to set. 1. Ignition OFF, disconnect the harness connector at the battery current sensor. Conditions for Setting the DTC 2. Ignition OFF, test for less than 1.0 ohm of resistance Module battery voltage between low voltage limits 6-9 between the low reference circuit terminal B and volts for a minimum of 2 seconds and serial data voltage...
Page 912 1J-19 Charging System: DTC B1516 Diagnostic Instructions • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic procedure. • Review “Strategy Based Diagnosis: ” for an overview of the diagnostic approach. • “Diagnostic Procedure Instructions - Vehicle Diagnostic Information: ” provides an overview of each diagnostic category.
Page 913 Charging System: 1J-20 Circuit/System Testing This vehicle has DTCs which include DTC symptoms. For more information, refer to “DTC Symptom 1. Ignition OFF, disconnect the harness connector at Description - Vehicle Diagnostic Information: ”. the battery current sensor. DTC Symptom DTC Symptom Descriptor 2.
Page 914 1J-21 Charging System: Step Action Value(s) Schematic Reference:“Starting and Charging Schematics: ” or “Power Distribution Schematics: ” and “Body Control System Schematics: ” Connector End View Reference:“Master Electrical Component List: ” Did you perform the Diagnostic System Check - Go to Vehicle? “Diagnostic System Check -...
Page 915 Charging System: 1J-22 DTC B1527 Reference Information Schematic Reference Diagnostic Instructions “Starting and Charging Schematics: ” • Perform the “Diagnostic System Check - Vehicle Connector End View Reference Diagnostic Information: ” prior to using this diagnostic “Engine Electrical Connector End Views: ” procedure.
Page 916 1J-23 Charging System: Conditions for Running the DTC Circuit/System Testing Key ON Test 1. Ignition OFF, disconnect the harness connector at the generator. • No generator, crankshaft position (CKP) sensors, or camshaft position (CMP) sensor DTCs are set. 2. Ignition ON, test for less than 1 volt between the generator turn on signal and ground.
Page 917 Charging System: 1J-24 Conditions for Running the DTC Circuit/System Verification Engine running, observe the scan tool ECM GEN-F • The vehicle speed is above 8 km/h (5 mph). Terminal Signal parameter. The parameter should read • The system voltage is between 9.5-18 volts. between 5-95 percent.
Page 918 1J-25 Charging System: Circuit/System Description Reference Information The engine control module (ECM) uses the generator Schematic Reference field duty cycle signal circuit to monitor the duty cycle of “Starting and Charging Schematics: ” the generator and fault indication. The generator field Connector End View Reference duty cycle signal circuit connects to the high side of the “Engine Electrical Connector End Views: ”...
Page 919 Charging System: 1J-26 DTC P0626 Conditions for Clearing the DTC Diagnostic Instructions • The ECM will command the message OFF after one trip in which the diagnostic test has been run and • Perform the “Diagnostic System Check - Vehicle passed.
Page 920 1J-27 Charging System: DTC C0899 Circuit/System Testing Diagnostic Instructions 1. Ignition OFF, disconnect the harness connector at the EBCM. • Perform the “Diagnostic System Check - Vehicle Diagnostic Information: ” prior to using this diagnostic 2. Ignition OFF, test for less than 1.0 ohm of resistance procedure.
Page 921 Charging System: 1J-28 Action Taken When the DTC Sets Symptoms - Engine Electrical • Traction Control System (TCS) and Vehicle Stability NOTE Enhancement System (VSES) disabled for the The following steps must be completed duration of the ignition cycle. before using the symptom tables. •...
Page 922 1J-29 Charging System: Charging System Test Step Action Value(s) Did you perform the Diagnostic System Check - Go to Vehicle? “Diagnostic System Check - — Go to Step 2 Vehicle Diagnostic Information: ” NOTE The battery must be above a 70 percent state Go to “Battery of charge.
Page 923 Charging System: 1J-30 Step Action Value(s) 1. Turn OFF all accessories. 2. Turn OFF the ignition. WARNING Make sure that the load is completely turned off before connecting or disconnecting a carbon pile load tester to the battery. Otherwise, sparking could ignite battery gasses which are extremely flammable and may explode violently.
Page 924 1J-31 Charging System: Step Action Value(s) 1. Maintain the engine speed at 2,500 RPM and continue to operate the generator at the load test value. 2. Measure the voltage drop from the output terminal 0.2 V Go to Step 14 Go to Step 16 of the generator to the positive terminal on the battery.
Page 925: Battery Charging
Charging System: 1J-32 Battery Charging Special tool J 42000 Battery Tester • For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts. • The charging area should be well ventilated. • Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test it using the J 42000 before charging.
Page 926 1J-33 Charging System: the charging current will increase. Extremely 5. Turn ON the charger and set to the highest setting discharged batteries may not activate the reversed for normal charging. voltage protection in some chargers. Refer to the 6. Inspect the battery every half hour after starting the manufacturer's instructions for operating this circuitry.
Page 927 Charging System: 1J-34 Battery Protection During Vehicle Storage 1. Position the vehicle with the booster battery so that Certain devices on the vehicle maintain a small the jumper cables will reach. continuous current drain, parasitic load, on the battery. A –...
Page 928 1J-35 Charging System: 11. The black negative (-) cable must be first 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the disconnected from the vehicle that was boosted (4). discharged battery. 12.
Page 929 Charging System: 1J-36 Charge Indicator Inoperative Step Action Did you perform the Diagnostic System Check - Vehicle? Go to “Diagnostic System Check - Go to Step 2 Vehicle Diagnostic Information: ” 1. Turn OFF the ignition. 2. Turn ON the ignition, with the engine OFF. Go to “Testing for Intermittent 3.
Page 930 1J-37 Charging System: Step Action Inspect the generator for a loose pulley and/or pulley nut. Go to Step 11 Go to Step 5 Is the generator pulley or pulley nut loose? 1. Loosen all of the generator mounting bolts. 2. Tighten the generator mounting bolts to specifications and in the proper sequence, if necessary.
Page 931 Charging System: 1J-38 Engine Cranks Slowly Inspect the following items: • Battery—Perform the Battery Inspection/Test. Refer to “Battery Inspection/Test”. • Wiring—Inspect the wiring for damage. Inspect all connections to the starter motor, the solenoid, the battery, and all ground connections. Refer to: –...
Page 932 1J-39 Charging System: • Use the correct terminal adapters. Do not use any common bolts or a combination of bolts, nuts, and or washers as adapters when testing the battery. Use the test adapters that are provided with the J 42000 or P/N 12303040 terminal adapters. If the adapters that are provided with the J 42000 require replacement, use P/N 12303040.
Page 933 Charging System: 1J-40 Step Action Values 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cable. 3. Clean and wire brush the lead face of both battery terminals and the metal contact rings in both cable connectors. 4. Remove the bolts from the cable connectors in —...
Page 934 1J-41 Charging System: Step Action Values 1. Connect the positive battery cable to the batteries positive terminal. CAUTION Refer to “Fastener Notice: ”. 17 N⋅m (13 lb 2. Tighten the positive battery cable bolt to the Battery OK — specified value. 3.
Page 935 Charging System: 1J-42 Load Test 10. Wait 1 minute. If the fuse blows, install an inductive ammeter and go to step 20. CAUTION 11. Remove the fused jumper wire. Do not turn the parasitic draw test switch to 12. Set a digital multimeter to the 10A scale. the OFF position with the engine running.
Page 936 1J-43 Charging System: b. When the vehicle has an unacceptable amount c. Repeat the parasitic current drain test procedure of parasitic current drain, remove each fuse one after any repair has been completed to make at a time until the current drain falls to an sure that the parasitic current drain is at an acceptable level.
Page 937 Charging System: 1J-44 8. Loosen the battery negative cable terminal bolt. 2. Insert the battery box cover (3) into the retaining (2). 9. Remove the battery negative cable from the battery. 3. Lock the side snap retainers (1). Installation Procedure 4.
Page 938 1J-45 Charging System: Battery Current Sensor Replacement Installation Procedure Removal Procedure 1. Squeeze the negative battery cable branches together. 1. Remove the negative battery cable. Refer to “Battery Negative Cable Replacement”. NOTE 2. Mark the location of the battery current sensor on the Ensure the battery current sensor is installed battery cable with tape for reference during in the correct direction and location on the...
Page 939 Charging System: 1J-46 Battery Negative Cable Replacement Removal Procedure NOTE • Always use replacement cables that are of the same type, diameter and length of the cables that you are replacing. • Always route the replacement cable the same way as the original cable. 6.
Page 940 1J-47 Charging System: Installation Procedure 6. Connect the body wiring harness electrical connector (4) to the battery current sensor (5). 1. Install the negative battery cable to the wiring loom and re-tape the loom. 7. Connect the negative battery cable electrical connector (7) to the body wiring harness electrical 2.
Page 941 Charging System: 1J-48 Battery Positive Cable Replacement Removal Procedure NOTE • Always use replacement cables that are of the same type, diameter and length of the cables that you are replacing. • Always route the replacement cable the same way as the original cable. 5.
Page 942 1J-49 Charging System: Installation Procedure 8. Install the battery box. Refer to “Battery Box Replacement”. 1. Install the positive battery cable to the wire loom and 9. Install the positive battery cable terminal (2) to the re-tape the loom. UBEC stud. 2.
Page 943: Battery Replacement
Charging System: 1J-50 Battery Replacement Removal Procedure 5. Disconnect the positive and negative battery cables. Refer to “Battery Negative Cable Disconnection and Connection”. 1. Remove the powertrain control module (PCM) (2) from the battery box cover (1) and relocate to the side.
Page 944 1J-51 Charging System: Installation Procedure 5. Position the battery lid (3) so that the alignment tabs (2) are in position. 1. Position the battery (1) in the battery box (2). 6. Lock the locking tabs (1) on the side of the battery 2.
Page 945 Charging System: 1J-52 Battery Tray Replacement Callout Component Name Preliminary Procedure Remove the battery box assembly. Refer to “Battery Box Replacement”. Battery Tray Upper Bolt (Qty: 2) CAUTION Refer to “Fastener Notice: ”. Tightening torque Tighten the bolts to 25 N⋅m (18 lb ft). Battery Tray Lower Bolt (Qty: 2) Tightening torque Tighten the bolts to 25 N⋅m (18 lb ft).
Page 946 1J-53 Charging System: 5. Remove the battery box mounting bolts. 3. Install the battery vent tube from the battery box. 6. Remove the battery box. 4. Install the battery. Refer to “Battery Negative Cable Disconnection and Connection”. Installation Procedure 5. Lock clips (2) from the battery vent tube (1). 1.
Page 947 Charging System: 1J-54 Generator Replacement Removal Procedure 7. Remove the idler pulley. Refer to “Drive Belt Idler Pulley Replacement: ”. 8. Remove the generator bolts. 1. Disconnect the negative battery cable. Refer to “Battery Negative Cable Disconnection and NOTE Connection”. When removing the generator from the 2.
Page 948 1J-55 Charging System: 4. Tighten the generator bolts in the sequence shown. Tightening torque Tighten the bolts to 50 N⋅m (37 lb ft). 7. Install the positive battery cable terminal to the generator. 8. Install the positive battery cable nut at the generator. 5.
Page 949 Charging System: 1J-56 Battery Usage Generator Usage Application Specification Application Specification Cold Cranking Amperage Generator Model 650 A (CCA) Rated Output 150 Amps Amp Hours 60 A/H Load Test Output 105 Amps Reserve Capacity 100 Minutes Replacement Model 47-7YR Number Special Tools and Equipment Special Tools - Engine Electrical Illustration...
Page 950 1K-1 Exhaust System: Exhaust System Precautions Exhaust Service Caution WARNING In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool. Hot Exhaust System Caution WARNING While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.
Page 951 Exhaust System: 1K-2 General Description Exhaust System Description NOTE Use of non-OEM parts may cause driveability concerns. The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable and into the exhaust muffler where exhaust noise is lessened. In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized.
Page 952 1K-3 Exhaust System: Resonator Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require specific exhaust tuning. Catalytic Converter The catalytic converter is an emission control device used to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas.
Page 953 Exhaust System: 1K-4 Diagnostic Information and Procedures Diagnostic Starting Point - Engine Exhaust Begin the system diagnosis by reviewing the exhaust system description. Reviewing the exhaust system description information will help familiarize you with the components of the exhaust system and the components intended function.
Page 954 1K-5 Exhaust System: Restricted Exhaust Special tool J 35314-A Exhaust Back Pressure Gage Diagnostic Aids WARNING Refer to “Hot Exhaust System Caution”. For dual exhaust systems a quick check of exhaust flow will help determine which side of the exhaust system is restricted.
Page 955 Exhaust System: 1K-6 Step Action Value(s) 1. Turn the engine OFF and place the ignition in the lock position. 2. Remove the J 35314-A. 3. Reinstall the HO2S sensor. Refer to “Heated Oxygen Sensor Replacement - Bank 1 Sensor 1: ” or “Heated Oxygen Sensor Replacement - Bank 2 Sensor 1: ”.
Page 956: Exhaust Leakage
1K-7 Exhaust System: Exhaust Leakage Condition Action WARNING Refer to “Hot Exhaust System Caution”. DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing noise. Refer to “Symptoms - Engine Exhaust”...
Page 957 Exhaust System: 1K-8 Repair Instructions Exhaust Manifold Replacement - Left Side 4. Remove the exhaust manifold bolts (1). Removal Procedure NOTE Do not reuse the gasket. WARNING Refer to “Exhaust Service Caution”. 5. Remove the exhaust manifold and gasket. Discard the gasket.
Page 958 1K-9 Exhaust System: 5. Install the catalytic converter to exhaust manifold 1. Remove the exhaust manifold heat shield. Refer to nuts (1). “Exhaust Manifold Heat Shield Replacement - Right Side”. Tightening torque 2. Remove the catalytic converter to exhaust manifold Tighten the nuts to 50 N⋅m (37 lb ft).
Page 959 Exhaust System: 1K-10 Installation Procedure 7. Install the exhaust manifold heat shield. Refer to “Exhaust Manifold Heat Shield Replacement - Right Side”. Exhaust Flexible Pipe Replacement Removal Procedure 1. Install one exhaust manifold bolt to the exhaust manifold. 2. Install the NEW exhaust manifold gasket onto the cylinder head and bolt.
Page 960 1K-11 Exhaust System: 4. Separate the exhaust flexible pipe from the catalytic CAUTION converters. Refer to “Fastener Notice: ”. 5. Remove the exhaust flexible pipe from the muffler. 6. Remove and discard the catalytic converter to 4. Tighten the exhaust muffler clamps. flexible pipe gaskets.
Page 961 Exhaust System: 1K-12 Catalytic Converter Replacement - Left Side Removal Procedure WARNING Refer to “Exhaust Service Caution”. WARNING Refer to “Protective Goggles and Glove Caution: ”. 5. Remove the left catalytic converter to exhaust flexible pipe bolts. 1. Remove the exhaust manifold heat shield. Refer to “Exhaust Manifold Heat Shield Replacement - Left Side”.
Page 962 1K-13 Exhaust System: Installation Procedure 5. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector. 1. Install a NEW catalytic converter to exhaust manifold gasket (2) onto the catalytic converter. 6. Lower the vehicle. 2. Install the catalytic converter to the vehicle. 3.
Page 963 Exhaust System: 1K-14 Catalytic Converter Replacement - Right Side Removal Procedure WARNING Refer to “Exhaust Service Caution”. WARNING Refer to “Protective Goggles and Glove Caution: ”. 5. Remove the right catalytic converter to exhaust flexible pipe nuts. 1. Remove the exhaust manifold heat shield. Refer to “Exhaust Manifold Heat Shield Replacement - Right Side”.
Page 964 1K-15 Exhaust System: Installation Procedure 5. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector. 1. Install a NEW catalytic converter to exhaust manifold gasket (1) onto the catalytic converter. 6. Lower the vehicle. 2. Install the catalytic converter to the vehicle. 3.
Page 965: Muffler Replacement
Exhaust System: 1K-16 Muffler Replacement Installation Procedure Removal Procedure 1. With the aid of an assistant, install the muffler assembly to the vehicle and the exhaust flexible 1. Raise and support the vehicle. Refer to “Lifting and pipe. Jacking the Vehicle: ”. 2.
Page 966 1K-17 Exhaust System: Catalytic Converter Heat Shield Replacement Removal Procedure NOTE The heat shields at the dash panel and the catalytic converter overlap and utilizing 1. Remove the muffler assembly. Refer to “Muffler common rivet attachment points. Replacement”. 4. Drill out the rivets. 2.
Page 967 Exhaust System: 1K-18 Exhaust Heat Shield Replacement - Dash Panel Removal Procedure CAUTION Refer to “Fastener Notice: ”. 1. Raise and support the vehicle. Refer to “Lifting and 3. Install the fuel tank strap bolt. Jacking the Vehicle: ”. Tightening torque 2.
Page 968 1K-19 Exhaust System: Installation Procedure Exhaust Manifold Heat Shield Replacement Removal Procedure 1. Position the dash panel heat shield to the underbody, installing the shield over the stud. 1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”. CAUTION 2.
Page 969 Exhaust System: 1K-20 Exhaust Manifold Heat Shield Replacement 5. Remove the exhaust manifold heat shield, sliding the shield up over the HO2S pigtail. - Right Side Removal Procedure Installation Procedure WARNING Refer to “Exhaust Service Caution”. WARNING Refer to “Protective Goggles and Glove Caution: ”.
Page 970 1K-21 Exhaust System: Exhaust Manifold Heat Shield Replacement 5. Remove the exhaust manifold heat shield, sliding the shield up over the HO2S pigtail. - Left Side Removal Procedure Installation Procedure WARNING Refer to “Exhaust Service Caution”. WARNING Refer to “Protective Goggles and Glove Caution: ”.
Page 971 Exhaust System: 1K-22 Exhaust Manifold Removal - Left Side 3. Remove the engine coolant temperature (ECT) sensor. Reference: “Oil Level Indicator and Tube Removal: ”. 4. Remove the left exhaust manifold lower bolts from 1. Remove the left exhaust manifold heat shield bolts. the left cylinder head.
Page 972 1K-23 Exhaust System: Exhaust Manifold Removal - Right Side Reference: “Oil Filter Adapter Removal: ”. 6. Remove the left exhaust manifold. 1. Remove the right exhaust manifold heat shield bolts. 7. Remove and discard the left exhaust manifold gasket. Reference: “Exhaust Manifold Cleaning and Inspection - 2.
Page 973 Exhaust System: 1K-24 3. Remove the right exhaust manifold bolts from the 6. Remove and discard the right exhaust manifold right cylinder head. gasket. 4. Remove the right exhaust manifold nuts from the 7. Remove the studs from the right cylinder head. studs in the right cylinder head.
Page 974 1K-25 Exhaust System: 9. Remove the right knock sensor heat shield. 12. Remove the crankshaft position (CKP) sensor bolt. 10. Remove the right knock sensor bolt. 13. Remove the CKP sensor. 11. Remove the right knock sensor. 14. Remove and discard the CKP sensor O-ring.
Page 975 Exhaust System: 1K-26 – Damage to the exhaust manifold mounting holes – Damage to the threaded holes (3) for the heat shield – Damage to the exhaust manifold flange bolt holes – Damage to the heated oxygen sensor (HO2S) hole threads (5) 15.
Page 976 1K-27 Exhaust System: Exhaust Manifold Cleaning and Inspection - Right Side Reference: “Exhaust Manifold Removal - Right Side: ”. Cleaning Procedure 1. Clean the exhaust manifold in solvent. WARNING Refer to “Safety Glasses Caution: ”. 2. Dry the exhaust manifold with compressed air. Inspection Procedure 2.
Page 977 Exhaust System: 1K-28 Exhaust Manifold Installation - Left Side Reference: “Exhaust Manifold Cleaning and Inspection - Left Side: ”. 3. Loosely install the left exhaust manifold upper bolts into the left cylinder head. 1. Install a NEW left exhaust manifold gasket. CAUTION Refer to “Fastener Notice: ”.
Page 978 1K-29 Exhaust System: 6. Install the engine coolant temperature (ECT) sensor. 8. Install the exhaust manifold heat shield bolts. Tightening torque Tightening torque Tighten the ECT sensor to 22 N⋅m (16 lb ft). Tighten the exhaust manifold heat shield bolts to 10 N⋅m (89 lb in).
Page 979 Exhaust System: 1K-30 CAUTION Refer to “Fastener Notice: ”. 4. Install the CKP sensor bolt. Tightening torque Tighten the CKP sensor bolt to 10 N⋅m (89 lb in). 2. Install a NEW crankshaft position (CKP) sensor O- ring. 5. Install the right knock sensor. 3.
Page 980 1K-31 Exhaust System: 7. Install the right knock sensor heat shield. 9. Install the studs into the right cylinder head. Tightening torque Tighten the studs to 10 N⋅m (89 lb in). 8. Install the right knock sensor heat shield bolts. Tightening torque Tighten the right knock sensor heat shield bolts 10.
Page 981 Exhaust System: 1K-32 14. Tighten the right exhaust manifold nuts and bolts. Tightening torque Tighten the right exhaust manifold nuts and bolts to 25 N⋅m (18 lb ft). 11. Install the right exhaust manifold. 15. Place the right exhaust manifold heat shield in position.
Page 982 1K-33 Exhaust System: Specifications Fastener Tightening Specifications - Engine Mechanical - 3.6L (LY7) Specification Application Metric English Crankshaft Position Sensor Bolt 10 N⋅m 89 lb in Crankshaft Position Sensor/Right Exhaust Manifold Lower Heat Shield Bolt 50 N⋅m 37 lb ft Engine Coolant Temperature (ECT) Sensor 22 N⋅m 16 lb ft...
Page 983 Table of Contents 2- i Section 2 Suspention CONTENTS Suspension General Diagnosis..... 2A–1 Lower Control Arm Replacement ..... 2B–16 Front Lower Control Arm Bushing Diagnostic Information and Procedures... 2A–1 Replacement (Rear Bushing)......2B–18 Diagnostic Starting Point - Strut Assembly Replacement......2B–18 Suspension General Diagnosis......
Page 984: Wheels And Tires
2- ii Table of Contents Trailing Arm Bracket Replacement ....2C–23 Tire Diagnosis - Irregular or Premature Wear ..2D–7 Adjustment Link Replacement ......2C–24 Tire Diagnosis - Waddle Complaint....2D–8 Spring Jounce Bumper Replacement ....2C–25 Tire and Wheel Inspection ......... 2D–9 Knuckle Replacement ........
Page 985 Suspension General Diagnosis: 2A-1 Suspension General Diagnosis Diagnostic Information and Procedures Diagnostic Starting Point - Suspension • “General Description: ” General Diagnosis • “General Description: ” Begin the system diagnosis by reviewing the system • “General Description: ” Description and Operation. Reviewing the Description and Operation information will help you determine the Visual/Physical Inspection correct symptom diagnostic procedure when a...
Page 986 2A-2 Suspension General Diagnosis: Vehicle Leads/Pulls Step Action DEFINITION: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle straight path. Did you review the General Description and perform the Go to “Symptoms - visual/physical inspections? Go to Step 2...
Page 987 Suspension General Diagnosis: 2A-3 Body Leans or Sways in Corners Step Action Did you review the General Description and perform the Go to “Symptoms - necessary inspections? Go to Step 2 Suspension General Diagnosis” Verify the vehicle leans or sways in corners. System OK Go to Step 3 Does the vehicle operate normally?
Page 988 2A-4 Suspension General Diagnosis: Torque Steer Step Action DEFINITION: On a dry, smooth, flat road, the vehicle has a left or right steering force only during acceleration. Did you review the General Description and perform the Go to “Symptoms - necessary inspections? Go to Step 2 Suspension General...
Page 989 Suspension General Diagnosis: 2A-5 Memory Steer Step Action DEFINITION: A lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Did you review the General Description and perform the Go to “Symptoms - necessary inspections?
Page 990 2A-6 Suspension General Diagnosis: Step Action Bounce the front of the vehicle in order to duplicate the noise. Go to Step 8 Go to Step 9 Did you duplicate the noise? 1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
Page 991 Suspension General Diagnosis: 2A-7 Noise Diagnosis - Rear Suspension Step Action DEFINITION: Any noise emitted from the rear of the vehicle that is induced by VEHICLE SPEED or DRIVING TERRAIN as related to the rear suspension. Did you review the General Description and perform the Go to “Symptoms - necessary inspections? Go to Step 2...
Page 992 2A-8 Suspension General Diagnosis: Wheel Bearings Diagnosis Step Action Values Did you review the General Description and perform the Go to necessary inspections? “Symptoms - — Go to Step 2 Suspension General Diagnosis” Road test the vehicle in order to verify the customer complaint.
Page 993 Suspension General Diagnosis: 2A-9 Suspension Strut and Shock Absorber Testing - On Vehicle Step Action Did you review the General Description and perform the Go to “Symptoms - necessary inspections? Go to Step 2 Suspension General Diagnosis” Verify that the customer concern is present. System OK Go to Step 3 Does the vehicle operate normally?
Page 994 2A-10 Suspension General Diagnosis: Ball Joint Inspection Step Action Values Did you review the General Description and perform the Go to necessary inspections? “Symptoms - — Go to Step 2 Suspension General Diagnosis” 1. Raise and support the vehicle. Refer to “Lifting and Jacking the Vehicle: ”.
Page 995 Suspension General Diagnosis: 2A-11 • Check for installed after market accessories or Measuring the Z Height modifications that could affect trim height measurement: – Larger of smaller than production wheels and tires – Lifting or lowering kits – Wheel opening flares or ground affects Measuring the P and R Heights NOTE The left and right P and R height difference...
Page 996 2A-12 Suspension General Diagnosis: NOTE 11. Re-measure the Z height as in step 4. 12. The true Z height is the average of the • In order to obtain the proper measurement, measurements taken in steps 4 and 8. Refer to “Trim D will equal inner minus the outer.
Page 997 Suspension General Diagnosis: 2A-13 Specification Application Metric English • The front curb height A (represented as (a) on the figure) is measured at a distance (c) 362 mm (14.25 in) from the center line of the vehicle. • The rear curb height B (represented as (b) on the figure) is measured at a distance (d) 362 mm (14.25 in) from the center line of the vehicle.
Page 998 2A-14 Suspension General Diagnosis: Measuring A or B Height Special Tools and Equipment Special Tools - Suspension General Tool Number/ Illustration Diagnosis Description Tool Number/ Illustration Description J 8001 Dial Indicator J 39570 Chassis Ear...
Page 999 Front Suspension: 2B-1 Front Suspension General Description General Description Front suspensions systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower The front suspension has 2 primary purposes: control arm assemblies through the stabilizer link and •...
Page 1000 2B-2 Front Suspension: Camber Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (−). The actual amount of toe is normally only a fraction of a degree.
Page 1001 Front Suspension: 2B-3 Negative thrust angle means the thrust line is pointing to • A slightly smaller diameter tire on the right front the left hand side (LHS) of the vehicle. increases a right torque lead. Inspect the front tires for If the thrust angle is out of specification, moving the axle differences in the brand, the construction, or the size.
Page 1002 2B-4 Front Suspension: Diagnostic Information and Procedures Vibration Analysis - Hub and/or Axle Input Test Description The numbers below refer to the step numbers on the diagnostic table: This test will determine the effect of turning input on the vibration. This test will determine the effect of an initial heavy torque load on the vibration.

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Table of Contents