1997 Buick LeSabre Service Repair Manual

1998 Buick Park Avenue
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1998-99 ENGINES 3.8L V6
1998-99 ENGINES
3.8L VG
MODEL IDENTIFICATION
MODEL IDENTIFICATION - CARS
Body Code (l)
Model
"C"
Park Avenue
"F"
Camaro & Firebird
"G"
Riviera
"H"
Bonneville, Eighty Eight, LeSabre, LSS & Regency
"W"
Grand Prix, Intrigue, Lumina, Monte Carlo & Regal
(1) Vehicle body code is fourth character of Vehicle Identification Number (VIN).
ENGINE IDENTIFICATION
Engine can be identified by eighth character of Vehicle Identification Number (VIN) which
is stamped on a metal pad located near lower left comer of windshield. See ENGINE
IDENTIFICATION CODES table. "W" in the tenth character of the VIN indicates 1998
model year, and "X" indicates 1999 model year.
Engine can also be identified by a 3-character engine code (RPO code). See ENGINE
IDENTIFICATION CODES table. This code may be stamped on engine. See Fig. 1 .

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1998-99 ENGINES 3.8L V6
Engine Code
& Partial VIN
Location
Optional
VIN Location
G91 E08084
Fig. 1: Locating Engine Codes

Courtesy of GENERAL MOTORS CORP.
ENGINE IDENTIFICATION CODES
Engine
3.8L SFI
8th Character Of Dash VIN
Engine Code (RPO Code)
3.8L SFI Supercharged
8th Character Of Dash VIN
Engine Code (RPO Code)
Code
K
L36
I
L67
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Hydraulic valve lifters are used. No valve adjustment is required.
TROUBLE SHOOTING
NOTE:
To trouble shoot mechanical engine components, see appropriate

table in TROUBLE SHOOTING - BASIC PROCEDURES article in

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1998-99 ENGINES 3.8L V6
GENERAL INFORMATION.
REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and
memory systems may lose memory data. Driveability
problems may exist until computer systems have
completed a relearn cycle. For 1998 models, see
COMPUTER RELEARN PROCEDURES - GENERAL MOTORS
article in GENERAL INFORMATION before disconnecting
battery. For 1999 models, see COMPUTER RELEARN
PROCEDURES - GENERAL MOTORS article in GENERAL
INFORMATION before disconnecting battery.
For reassembly reference, label all electrical connectors, vacuum
hoses and fuel lines before removal. Also place mating marks on
engine hood and other major assemblies before removal.
NOTE:
FUEL PRESSURE RELEASE
Disconnect negative battery cable. Loosen fuel tank filler cap. Connect Fuel Pressure Gauge
(J-34730-1) to fuel line fitting (wrap shop towel around fitting to absorb leakage). Place
gauge bleed hose into container. Open bleed valve to release pressure.
COOLING SYSTEM BLEEDING
Except "W" Body
1. Fill radiator to base of filler neck. Start engine. Place A/C-heater control in any position
except MAX. Select highest temperature setting. Idle engine until lower radiator hose is
hot.
2. Increase engine speed to 3000 RPM and then back to idle. Do this 5 times to expel any
air trapped in system. Fill radiator as necessary. Install radiator cap. Allow engine to
cool. Fill coolant recovery reservoir as necessary.
"W" Body
Open air bleed valve on thermostat housing. Fill radiator until coolant level is even with
filler neck and no air bubbles are coming out of air bleed valve. Close air bleed valve. Install
radiator cap. Fill coolant reservoir. Warm engine. Allow engine to cool. Fill radiator and
coolant reservoir.
POWER STEERING BLEEDING
CAUTION: If air was introduced into hydraulic system during

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1998-99 ENGINES 3.8L V6
servicing, bleed system. Aerated fluid, which appears Light

Tan in color, results in poor steering performance and will
cause pump damage.
1. Tum ignition off. Raise and support vehicle with front wheels off ground. Tum wheels
fully to left. Add power steering fluid to FULL COLD mark on dipstick. Tum wheels
from side to side at least 20 times, but DO NOT touch steering stops. Add fluid as
necessary to maintain level at FULL COLD mark.
2. Start engine. With engine idling, check fluid level. Add fluid as necessary to bring fluid
level to FULL COLD mark. Return wheels to center position. Lower vehicle. Continue
to run engine for 2 to 3 minutes to raise temperature of fluid and eliminate trapped air.
Tum steering wheel in both directions.
3. Road test vehicle. Check for leaks. Ensure fluid level is at FULL HOT mark when fluid
is stabilized at operating temperature.
ENGINE
Removal & Installation (Except "W" & "F" Bodies)
1. Remove hood. Disconnect battery cables. Release fuel pressure. See FUEL
PRESSURE RELEASE. Drain cooling system. Drain engine oil. Remove strut tower
cross brace (if equipped). Remove windshield washer, radiator and heater supply hoses.
2. Disconnect electrical connectors as necessary. Remove serpentine belt. Remove power
steering pump (leave hoses attached). Remove airflow duct and air cleaner. Disconnect
cables and hoses from throttle body. Remove ignition coil ground strap.
3. Disconnect fuel lines and vacuum hoses. Disconnect upper engine strut. Raise and
support vehicle. Disconnect exhaust pipe. Disconnect engine mount bolts. Attach a
suitable lifting hook and chain to engine lifting brackets. Raise engine slightly to take
weight off mounts.
4. Remove A/C compressor (leave hoses attached). Disconnect engine oil cooler lines (if
equipped). Remove front engine mount and right front engine-to-transaxle bracket.
Support transaxle. Remove bolts securing transaxle to engine.
5. Remove flexplate cover. Mark flexplate in relation to torque converter for reassembly
reference. Remove torque converter bolts. Remove starter. Separate transaxle from
engine. Lift engine out of vehicle.
6. To install, reverse removal procedure. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING . Fill and bleed power steering system. See POWER
STEERING BLEEDING . Tighten bolts to specification. See TORQUE
SPECIFICATIONS table.
Removal & Installation ("F" Body)
1. Disconnect negative and positive battery cables. Discharge A/C system using approved

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1998-99 ENGINES 3.8L V6
2.
3.
4.
5.
6.
refrigerant recovery/recycling equipment. Relieve fuel pressure. See FUEL

PRESSURE RELEASE . Disconnect A/C compressor and condenser hose from
accumulator. Plug openings. Raise and support vehicle. Remove front tires. Drain
coolant and engine oil.
Remove heated oxygen sensors. Remove catalytic converter bolts. Remove exhaust
pipe clamp bolt at catalytic converter and remove catalytic converter. Remove front
fascia lower deflectors and stabilizer bar bushing bolts. Remove radiator inlet hose.
On A/T models, remove torque converter bolts. Disconnect transmission fluid oil
cooler lines. Disconnect transmission range selector lever cable from transmission.
Remove left and right transmission support brackets.
On MIT models, disconnect transmission control lever handle. Remove clutch actuator
cylinder line from actuator. On all models, remove driveshaft. Remove torque arm from
transmission.
Remove steering gear coupling shaft from rack and pinion. Remove ground strap.
Remove starter. Disconnect A/C compressor and condenser hose from compressor and
condenser. Remove negative battery cable from rear compressor bracket mounting
stud.
Lower vehicle. Remove heater hoses from drive belt tensioner. Remove air cleaner.
Disconnect fuel lines at fuel rail. disconnect cruise control cable from throttle body.
Disconnect accelerator control cable from throttle body. Remove radiator outlet hose
from thermostat housing.
WARNING: To avoid personal injury, gear tension relief function
of scan tool must be performed prior to disconnecting
ABS hydraulic modulator. See appropriate ANTI-LOCK
article in BRAKES.
7. Disconnect brake booster vacuum hose. Using scan tool, perform gear tension relief
sequence. See appropriate ANTI-LOCK article in BRAKES. Disconnect
BRAKELINES and clips from ABS hydraulic modulator. Remove right-hand body
hinge pillar trim panel. Disconnect engine wiring harness connectors. Disconnect
forward lamp wiring harness connectors.
8. Disconnect Powertrain Control Module (PCM) and harness, and place on top of engine.
Pull engine wiring harness through front dash. Place harness on top of engine.
Disconnect positive lead at generator. Remove lower shock attachment nuts and bolts
from lower control arms. Remove upper control arm ball stud from steering knuckle.
Use upper control arm to secure struts.
9. Disconnect electrical connectors to wheel speed sensors at engine frame. Position
engine support under engine frame. Remove engine frame and transmission support
bolts. Lower engine, transmission and engine frame. Remove transmission. On MIT
models, remove clutch housing and clutch. On all models, remove engine mount
through-bolts. Remove engine from engine frame.

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1998-99 ENGINES 3.8L V6
SYSTEM BLEEDING . Tighten bolts to specification. See TORQUE
Removal & Installation ("W" Body)
1. Remove hood. Disconnect negative battery cable. Release fuel pressure. See FUEL
PRESSURE RELEASE . Remove air cleaner. Disconnect fuel lines from fuel rail.
Remove coolant recovery bottle, inner fender electrical cover, and fuel injector cover.
Disconnect throttle cables.
2. Remove heat shield from exhaust crossover pipe. Remove throttle cable bracket and
vacuum line as an assembly. Remove exhaust crossover pipe. Remove engine torque
strut from between engine and top of radiator panel. Drain cooling system. Disconnect
oil cooler hoses from radiator.
3. Remove serpentine belt. Remove power steering pump. Where necessary to gain
clearance, remove washer reservoir, diagonal braces, cooling fans, generator and
generator support bracket with ignition coil pack. Raise and support vehicle. Remove
flexplate cover. Mark flexplate in relation to torque converter for reassembly reference.
Remove torque converter bolts. Remove A/C compressor (leave hoses attached).
Remove starter.
4. Remove bolts securing transaxle mount to engine. Remove nuts securing engine mount
to frame. Disconnect oil cooler pipes. Disconnect exhaust pipe from manifold. Lower
vehicle. Remove bolts securing transaxle to engine. Separate transaxle from engine.
Lift engine out of vehicle.
SYSTEM BLEEDING . Fill and bleed power steering system. See POWER
STEERING BLEEDING . Tighten bolts to specification. See TORQUE
INTAKE MANIFOLD (UPPER)
NOTE:
On supercharged engine VIN 1), supercharger acts as an upper

intake manifold. See SUPERCHARGER .
Removal (All Except "F" Body)
1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative

battery cable. Drain cooling system. Remove throttle body air intake duct.
2. Remove fuel injector sight shield. Disconnect right bank spark plug wires and set aside.
Disconnect evaporative emissions canister purge solenoid valve harness connector.
Remove fuel rail. Disconnect brake booster vacuum hose. Remove EGR heat shield.
3. Remove throttle cable bracket as necessary and set aside. Remove throttle body support
bracket. Disconnect MAP sensor harness connector. Remove upper intake manifold

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1998-99 ENGINES 3.8L V6
bolts, upper intake manifold and gasket.

Removal ("F" Body)

battery cable. Drain cooling system. Disconnect the Intake Air Temperature (IAT)
sensor harness connector. Remove throttle body air intake duct.
2. Remove serpentine belt. Disconnect wiring at generator. Disconnect and remove
evaporative canister purge solenoid. Remove generator bolts and generator.
CAUTION: The drive belt tensioner must be rotated, if it is difficult
to remove. Pulling the tensioner from top may damage
the engine front cover. If necessary, break the plastic
thermostat bypass upper pipe to allow rotation of the
drive belt tensioner and replace the pipe during
installation.
3. Remove heater hoses from drive belt tensioner. Remove drive belt tensioner bolts.
Remove drive belt tensioner. Disconnect vacuum hoses and electrical connectors as
necessary. Remove evaporative emissions canister purge solenoid valve. Remove
intake manifold vacuum source fitting from upper intake manifold, just above fuel rail.
4. Remove Idle Air Control (IAC) valve. Disconnect fuel feed and return pipes from fuel
rail. Disconnect EVAP pipe at engine. Disconnect cruise control and accelerator cables
from throttle body. Remove cruise control and accelerator cables from throttle body
cable bracket as necessary. Remove throttle body cable bracket bolts and throttle body
cable bracket.
5. Disconnect ignition control module harness connector. Reference mark spark plug
wires at ignition coils. Disconnect spark plug wires at ignition coils and set aside.
Remove ignition control module/coil assembly mounting bolts/nuts. Remove ignition
control module/coil assembly.
6. Remove generator brace-to-lower intake manifold bolts. Remove generator brace from
lower intake manifold. Remove throttle body-to-upper intake manifold bolts. Remove
throttle body from upper intake manifold.
7. Remove EGR valve outlet pipe retaining bolt and nut. Remove EGR valve outlet pipe.
Disconnect upper radiator hose at thermostat housing. Remove thermostat housing
bolts, thermostat housing and thermostat.
8. Disconnect fuel injector harness connectors. Using compressed air, clean dirt from
injector bores, near bottom of injectors. Remove fuel rail retaining nuts. Remove fuel
rail and set aside. Remove upper intake manifold bolts, upper intake manifold and
gasket.
Installation

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1998-99 ENGINES 3.8L V6
1. Ensure sealing surfaces, bolt threads and bolt holes are clean. Install upper intake
manifold and NEW gasket.
2. Coat bolt threads with thread locking compound. Tighten upper intake manifold bolts
in sequence to specification. See Fig. 2 or Fig. 3 . See TORQUE
SPECIFICATIONS .
3. Lubricate fuel rail "O" rings with clean engine oil. To complete installation, reverse
removal procedure. Fill and bleed cooling system. See COOLING SYSTEM
BLEEDING.
G97D03613
Fig. 2: Upper Intake Manifold Bolt Tightening Sequence VIN "K" ("F" Body)

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1998-99 ENGINES 3.8L V6
G97B03612
Fig. 3: Upper Intake Manifold Bolt Tightening Sequence VIN "K" (Except "F" Body)
INTAKE MANIFOLD (LOWER)
Removal
1. On VIN "K", remove upper intake manifold. See INTAKE MANIFOLD (UPPER).
On VIN "I", remove supercharger. See SUPERCHARGER.
2. On all models, remove spark plug wires and fuel rail (if not previously removed).
Remove exhaust crossover heat shield and power steering pump bracket. Remove
serpentine belt, generator and generator bracket (if not previously removed). Remove
cable bracket, heater pipes and by-pass hose.
3. Remove lower intake manifold bolts. On VIN "K", 2 bolts are hidden in right front and
left rear comers of lower intake manifold. On all models, remove lower intake
manifold, gaskets and seals.

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1998-99 ENGINES 3.8L V6
Installation
1. Ensure sealing surfaces and bolt threads and holes are clean. Apply GM Sealant
(12345336) at end of seals on cylinder block. Install manifold and gaskets. Coat bolt
threads with thread locking compound.
2. Tighten the intake manifold bolts in sequence to specification. See Fig. 4 or Fig. 5 . See
TORQUE SPECIFICATIONS . Lubricate fuel rail "O" rings with engine oil. To
complete installation, reverse removal procedure. Fill and bleed engine cooling system.
See COOLING SYSTEM BLEEDING .
G97J03611
Fig. 4: Lower Intake Manifold Bolt Tightening Sequence - "F" Body


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1998-99 ENGINES 3.8L V6
G97H03610
Fig. 5: Lower Intake Manifold Bolt Tightening Sequence - Except "F" Body (VIN "K"
Shown, VIN "1" Is Similar)
EXHAUST MANIFOLDS
NOTE:
Not all components need to be removed on all models. Remove

as necessary for access and clearance.
Removal & Installation (Left -All Except "F" Body)
1. Disconnect negative battery cable. Remove air inlet duct. Disconnect spark plug wires.
Remove crossover pipe from manifold. On some models, it may be necessary to
remove cooling fan and/or radiator hose for clearance.
2. On all models, remove engine lift hook and manifold heat shield (if equipped). Remove
oil dipstick tube and oil dipstick. Remove exhaust manifold bolts, exhaust manifold and
gasket. To install, reverse removal procedure using NEW gasket. Tighten fasteners to

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1998-99 ENGINES 3.8L V6
specification. See TORQUE SPECIFICATIONS .

Removal & Installation (Left - "F" Body)
1. Raise and support vehicle. Disconnect the left heated oxygen sensor electrical
connector from the wire support bracket. Remove the left heated oxygen sensor.
Remove the exhaust pipe-to-exhaust manifold bolts.
2. Disconnect left bank spark plug wires at the spark plugs and move aside. Remove spark
plugs from cylinders No. 3 and 5. Remove the two rear exhaust manifold-to-cylinder
head nuts/bolts. Lower vehicle.
CAUTION: When removing the EGR inlet tube from the left
exhaust manifold, inspect the pipe for leaks during
installation. Replace the EGR adapter if the pipe leaks.
3. Remove the EGR inlet pipe bolt and nuts. Remove the EGR inlet pipe from the exhaust
manifold.
4. Remove spark plug from cylinder No. 1. Remove the exhaust manifold heat shield nuts.
Remove the exhaust manifold heat shields. Remove the remaining exhaust manifold-tocylinder head nuts/bolts. Remove the exhaust manifold. Remove the exhaust manifold
gasket.
5. To install, reverse removal procedure using NEW gasket. Tighten fasteners to
Removal & Installation (Right -All Except "F" Body)
NOTE:
Whenever right exhaust manifold pipe is removed, inspect EGR

outlet pipe for leaks. If any leaks exist, replace EGR adapter.
1. Disconnect negative battery cable. Remove air inlet duct. Remove throttle cable from
throttle body. Remove brake booster hose. Remove serpentine belt and power steering
pump bracket with hoses attached, and position aside.
2. Drain cooling system. Disconnect spark plug wires and oxygen sensor. Disconnect
crossover pipe and exhaust pipe from manifold. Remove transaxle dipstick tube and
dipstick.
3. Remove manifold heat shield (if equipped). Remove catalytic converter heat shield and
pipe hanger. Remove exhaust pipe-to-exhaust manifold nuts/bolts. Remove engine lift
bracket. Remove exhaust manifold bolts, exhaust manifold and gasket.
4. To install, reverse removal procedure using NEW gasket. Tighten fasteners to
Removal & Installation (Right - "F" Body)
1. Raise and sunnort vehicle. Remove the right heated oxvgen sensor electrical connector

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1998-99 ENGINES 3.8L V6
2.
3.
4.
5.
from the lift bracket. Remove the right heated oxygen sensor. Remove the exhaust
pipe-to-exhaust manifold bolts.
Disconnect spark plug wires at cylinders No. 4 and 6 and move aside. Remove cylinder
No. 6 spark plug. Remove the two rear exhaust manifold-to-cylinder head nuts/bolts.
Lower vehicle.
Disconnect spark plug wire at cylinder No. 2. Remove spark plugs from cylinders No. 2
and 4. Remove the exhaust manifold heat shield nuts. Remove the exhaust manifold
heat shields.
Remove the remaining exhaust manifold-to-cylinder head nuts/bolts. Remove the
exhaust manifold. Remove the exhaust manifold gasket.
To install, reverse removal procedure using NEW gasket. Tighten fasteners to
SUPERCHARGER
Removal

battery cable. Partially drain cooling system. Remove accessory drive belt from
supercharger pulley. Remove fuel injector shield. Disconnect fuel lines from fuel rail.
Disconnect vacuum hoses as necessary.
2. Disconnect electrical connectors from fuel injectors. Remove electrical harness shield.
Disconnect electrical harness from front of supercharger. Remove fuel rail and injectors
as an assembly. Disconnect electrical connectors as necessary. Remove air intake duct.
Disconnect EGR pipe, throttle cable, and cruise control cable from supercharger.
Remove boost pressure/vacuum hose block. Remove cable bracket.
3. Remove stud securing tensioner bracket to supercharger (use a stud remover or jam-nut
procedure, if necessary). This stud must be removed to allow supercharger to clear
lower intake locator pins. Remove throttle body from supercharger. Remove
supercharger bolts, supercharger and gasket.
Installation
Install NEW supercharger gasket. DO NOT use sealant on supercharger gasket. Install
supercharger. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. To
complete installation, reverse removal procedure.
CYLINDER HEAD
NOTE:

Removal (All Except "F" Body)

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1998-99 ENGINES 3.8L V6
1. Remove the upper and lower intake manifold. See INTAKE MANIFOLD (UPPER)
and INTAKE MANIFOLD (LOWER). Remove exhaust manifold. See EXHAUST
MANIFOLDS.
2. On front cylinder head applications, disconnect spark plug wires. Remove engine lift
bracket and rocker arm cover. Remove exhaust crossover pipe and cooling fan.
Remove generator. Remove ignition coil and bracket. Remove A/C compressor bracket
bolt.
3. On rear cylinder head, disconnect spark plug wires. Remove exhaust crossover pipe.
Remove power steering pump with hoses attached, and position aside. Remove heater
pipe from front cover housing. Remove transaxle dipstick tube and dipstick.
4. Remove rocker arms, push rods and guide plates. See ROCKER ARMS & PUSH
RODS . Remove cylinder head bolts, and discard. Remove cylinder head and gasket.
Removal ("F" Body)
1. Remove the upper and lower intake manifold. See INTAKE MANIFOLD (UPPER)
and INTAKE MANIFOLD (LOWER). Remove exhaust manifold. See EXHAUST
MANIFOLDS.
2. Unbolt any accessories attached to ends of cylinder head. Remove rocker arm covers,
rocker arms & push rods. See ROCKER ARMS & PUSH RODS .
3. Remove cylinder head bolts. Remove cylinder head and gasket.
Inspection
Inspect cylinder head for warpage. See CYLINDER HEAD under OVERHAUL.
Installation
1. Ensure cylinder head bolt threads and cylinder block holes are clean. Ensure all gasket
holes align with cylinder block and arrow on gasket is pointing to front of engine.
Apply GM Sealant (1052080) to cylinder head bolt threads.
2. Install NEW cylinder head gasket. Tighten bolts to specification in sequence. See
TORQUE SPECIFICATIONS table. See Fig. 6 . To complete installation, reverse
removal procedure.

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1998-99 ENGINES 3.8L V6
G90A04729
Fig. 6: Cylinder Head Bolt Tightening Sequence

FRONT COVER SEAL
Removal
Disconnect negative battery cable. Remove serpentine belt. Raise and support vehicle. On all
models except "F" body, remove right front wheel and inner splash shield. On all models,
remove crankshaft pulley/balancer bolt and crankshaft pulley/balancer. Pry seal from front
cover and discard seal.
Installation
Coat seal with oil. Using Seal Installer (J-35354) and crankshaft pulley/balancer bolt, install
seal. Remove seal installer. Coat sealing surface of crankshaft pulley/balancer with oil. To
complete installation, reverse removal procedure. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS.
FRONT COVER
Removal

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1998-99 ENGINES 3.8L V6
1. Disconnect negative battery cable. Drain cooling system and crankcase oil. Remove
serpentine belt. Remove water pump pulley. Disconnect heater pipes. Disconnect
coolant hoses from front cover.
2. Raise and support vehicle. On all models except "F" Body, remove right front wheel
and inner splash shield. On all models, remove crankshaft balancer bolt. Remove
crankshaft balancer. Disconnect electrical connections at oil pressure sender, camshaft
sensor and crankshaft sensor.
3. Remove bolts securing front cover to oil pan. Remove power steering pump (leave
hoses attached). Remove remaining bolts, front cover and gasket. See Fig. 7 .
Installation
1. Replace timing chain and sprockets if worn. See TIMING CHAIN & SPROCKETS.
Install NEW front cover gasket. Coat front cover bolt threads with Sealant (1052080).
Install NEW crankshaft balancer bolt. To install, reverse removal procedure. Install
crankshaft sensor and shield.
2. Install Crankshaft Sensor Gauge (J-37089) onto rear of crankshaft balancer. See Fig. 8 .
If gauge contacts balancer at any point, replace crankshaft balancer. To complete
installation, reverse removal procedure. Coat sealing surface of crankshaft balancer and
seal with oil. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
+FRONT OF ENGINE
Water Pump
G93F39912
Fig. 7: Removing Front Cover


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1998-99 ENGINES 3.8L V6
Crankshaft
Balancer
Crankshaft
Sensor Gauge
Crankshaft
Sensor
G93F39920
Fig. 8: Checking Crankshaft Balancer Clearance

TIMING CHAIN & SPROCKETS
Removal
1. Remove front cover. See FRONT COVER . Inspect timing chain and sprockets for
wear. Timing chain in-and-out movement should not exceed l" (25.4 mm). Replace
components as necessary.
2. Rotate crankshaft to align timing marks on camshaft and crankshaft sprockets. See Fig.
2. Remove timing chain damper assembly. Remove camshaft sprocket bolts, and
discard. Remove camshaft sprocket and timing chain. Remove crankshaft sprocket.
NOTE:
If balance shaft has been moved, ensure alignment is correct

before installing timing chain and sprockets. See BALANCE
SHAFT.
Installation
1. If engine has been rotated, rotate the crankshaft so No. 1 cylinder is at TDC.
Temporarily install camshaft sprocket. Rotate camshaft sprocket so timing mark points
downward.

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1998-99 ENGINES 3.8L V6
2. Install timing chain on camshaft and crankshaft sprockets. Align timing marks. See Fig.
2 . Install NEW camshaft sprocket bolts. Install timing chain damper. Rotate engine 2
revolutions. Ensure timing marks are aligned. To complete installation, reverse removal
procedure.

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1998-99 ENGINES 3.8L V6
Camshaft
Gear (3.BL Only)
Camshaft
Sprocket
Woodruff
Key
Crankshaft
Sprocket
Align
Marks
0
Align
Marks
BALANCE SHAFT
TO CAMSHAFT
(3.8L ONLY)
CAMSHAFT TO
CRANKSHAFT
(ALL MODELS)
G93J39932
Fig. 9: Exploded View Of Timing Chain & Sprockets

ROCKER ARMS & PUSH RODS

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1998-99 ENGINES 3.8L V6
NOTE:

Removal
1. Disconnect negative battery cable. Remove serpentine belt. To remove left rocker arm
cover, remove generator bracket and spark plug wires. On all models except "F" body,
disconnect torque strut (if equipped) at radiator support. Remove torque strut bracket
bolts at manifolds. Remove engine lift bracket.
2. On all models, to remove right rocker arm cover, loosen power steering pump bolts,
and move pump forward with hoses still attached. Remove power steering pump
brackets. Remove spark plug wires.
3. On either side, remove rocker arm cover. Remove and discard rocker arm pivot bolts.
Mark rocker arm component locations for reassembly reference. Remove rocker arms
and components. See Fig. 10.
Installation
To install, reverse removal procedure. Apply Prelube (GM PIN 12345501) or equivalent, to
any bearings and friction surfaces. Using NEW bolts, coat rocker arm bolt threads with
thread Threadlock (12345493). Apply thread sealant to rocker arm cover bolt threads.
Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

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1998-99 ENGINES 3.8L V6
Rocker Arm
Valve Lifter
Guide
Push Rod
Valve
~
Lifter ~
..
l
Pivot
G93B39942
Fig. 10: Exploded View Of Rocker Arm & Components

VALVE LIFTERS
Removal
Remove upper and lower intake manifold. See INTAKE MANIFOLD (UPPER) and
INTAKE MANIFOLD (LOWER). Remove rocker arm covers, rocker arms and push
rods. See ROCKER ARMS & PUSH RODS . Remove valve lifter guide and valve lifters.
See Fig. 10 . Mark component locations for reassembly reference.
Installation
Coat valve lifters with Engine Oil Supplement (1052365). Install components in original
location. To complete installation, reverse removal procedure. Tighten fasteners to
CAMSHAFT
Removal
1. Disconnect negative battery cable. On all models except "F" body, remove engine. See
RNGTNR.

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1998-99 ENGINES 3.8L V6
2. On "F" body, Remove air cleaner assembly. Drain cooling system into suitable
container. Recover refrigerant using approved refrigerant recovery/recycling
equipment. Disconnect upper and lower hoses at radiator. Remove evaporator tube bolt
near condenser. Disconnect and cap evaporator tube at condenser. Disconnect upper oil
cooler line at radiator (if equipped).
3. Raise and support vehicle. Disconnect lower oil cooler line at radiator (if equipped).
Remove condenser tube nut. Remove condenser tube from condenser. Lower vehicle.
Remove the coolant recovery reservoir hose from the radiator. Remove electric fan
assembly. Remove radiator and condenser as an assembly.
4. On all models, remove upper and lower intake manifold. See INTAKE MANIFOLD
(UPPER) and INTAKE MANIFOLD (LOWER). Remove rocker arms and push
rods. See ROCKER ARMS & PUSH RODS .
5. Remove valve lifters. Remove timing chain and sprockets. See TIMING CHAIN &
SPROCKETS. Remove camshaft thrust plate and camshaft. Using Remover/Installer
(J-33049), remove camshaft bearings (if necessary).
Inspection
Measure camshaft journal diameter, lobe lift and oil clearance. Replace components if not
within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.
Installation
Install camshaft bearings (if removed). Ensure oil holes are aligned. Coat camshaft journals
and lobes with Lubricant (1052365). Install camshaft. Install components in original
locations. Apply Sealant (1052914) to camshaft rear plug. To complete installation, reverse
removal procedure. Ensure timing marks are aligned. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS.
BALANCE SHAFT
NOTE:
Balance shaft removal procedure provided by manufacturer is

with engine removed from vehicle. It may not be necessary to
remove engine on some models for balance shaft removal.
Removal
1. Disconnect negative battery cable. Remove engine. See ENGINE . Remove

flexplate/flywheel. Remove upper and lower intake manifolds. See INTAKE
MANIFOLD (UPPER) and INTAKE MANIFOLD (LOWER). Remove lifter
guide. See Fig. 10 .
2. Remove front cover. See FRONT COVER . Remove and discard balance shaft gear
bolt. See Fig. 11 . Remove camshaft sprocket and timing chain. See TIMING CHAIN
& SPROCKETS. Remove balance shaft retainer and gear. See Fig. 11 . Using Slide

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1998-99 ENGINES 3.8L V6
Hammer (J-6125-lB), remove balance shaft from front of engine.
NOTE:
Balance shaft and bearings are serviced as a complete

assembly only. Use specified installation tools to prevent
balance shaft damage.
3. Remove balance shaft plug from rear of cylinder block. Note direction of rear bearing
installation. Using Balance Shaft Bearing Remover/Installer (J-36995), remove
bearings from block. See Fig. 12 .
Inspection
Replace components if damaged or not within specification. See BALANCE SHAFT

Installation
1. Lubricate balance shaft bearings with engine oil. Install NEW front and rear bearings
using Balance Shaft Bearing Remover/Installer. On rear bearing, be sure rolled edge
faces inward, toward engine, and manufacturer's marking faces flywheel side of engine.
See Fig. 12.
2. Using Balance Shaft Installer (J-36996), install balance shaft. Temporarily install
balance shaft retainer and bolts. Install balance shaft gear. Apply GM Threadlock
(12345493) to NEW gear bolt, and install bolt. Tighten gear bolt to specification. See
TORQUE SPECIFICATIONS table.
3. Install balance shaft rear plug. Using dial indicator, measure balance shaft end play and
radial clearance at front and rear of balance shaft. See Fig. 13 . Replace components if
measurements are not within specification. See BALANCE SHAFT
4. Rotate camshaft so timing mark is pointing downward when sprocket is installed. With
camshaft sprocket and gear removed, rotate balance shaft so timing mark on gear is
pointing downward.
5. Rotate balance shaft to align timing marks on camshaft gear and balance shaft gear, and
install camshaft gear. See Fig. 9 . Rotate crankshaft so No. 1 piston is at TDC. Install
timing chain and sprocket. Ensure timing marks are aligned. See Fig. 9 .
6. Using dial indicator, measure gear lash at 4 places, every 1/4 tum. Gear lash should be
within specification. See BALANCE SHAFT SPECIFICATIONS table.
7. If measurements are within specification, tighten balance shaft retainer bolts to
specification. See TORQUE SPECIFICATIONS table. To complete installation,
reverse removal procedure.
BALANCE SHAFT SPECIFICATIONS

Application
In. (mm)I

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1998-99 ENGINES 3.8L V6
Bearing Bore I.D.

Front
Rear
End Play
Gear Lash
Radial Clearance
Front
Rear
2.0462-2.0472 (51.973-51.999)
1.8735-1.8745 (47.584-47.612)
0-.0067 (0-.171)
.002-.005 (.05-.13)
0-.0010 (0-.026)
.0005-.0043 (.013-.109)
Balance
Shaft Retainer
Front
Bearing
Rear
Bearing
Balance Shaft
Rear Plug
~b
[,C,C
Balance
Shaft
G95A13227
Fig. 11: Identifying Balance Shaft & Components


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1998-99 ENGINES 3.8L V6
1-4----
Rear Bearing
Installer
(J-36995-1)
Rear Bearing
Remover
,.....,.__ _ _ _ (J-36995-5)
.-.
("\
REMOVAL
G95C13229
Fig. 12: Replacing Balance Shaft Rear Bearing


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1998-99 ENGINES 3.8L V6
Dial Indicator
MEASURING END PLAY
MEASURING FRONT
RADIAL CLEARANCE
Dial Indicator
MEASURING GEAR LASH

G95G13231
Dial
Indicator
MEASURING REAR
RADIAL CLEARANCE
Fig. 13: Measuring Balance Shaft Clearances

CRANKSHAFT REAR OIL SEAL
NOTE:
If rear oil seal housing has been removed, see CRANKSHAFT

REAR OIL SEAL HOUSING before installing new seal.
Removal
1. Remove transaxle. For A/T, see REMOVAL & INSTALLATION - CARS EXCEPT METRO & PRIZM article in AUTOMATIC TRANSMISSIONS. For MIT,
see appropriate article in CLUTCHES.
2. Use Flywheel Holding Tool (J-37096) to prevent crankshaft rotation. Remove the eight
bolts attaching the engine flywheel to the crankshaft flange and discard them. See Fig.

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1998-99 ENGINES 3.8L V6
14 . Remove the flywheel.
CAUTION: DO NOT damage the crankshaft OD surface or chamfer

with any tool.
3. Confirm the crankshaft rear oil seal leak. Insert a flat-bladed tool through the dust lip at
an angle. Pry out the crankshaft rear oil seal by moving the handle of the tool towards
the end of the crankshaft. Repeat as necessary around the crankshaft rear oil seal.
4. Inspect the ID of the bore. Correct or replace the crankshaft rear oil seal housing as
required. Inspect the crankshaft for nicks or burrs on the surface that contacts the
crankshaft rear oil seal. Repair or replace the crankshaft as required.
800255789
Fig. 14: Removing/Installing Flywheel

Installation
NOTE:
Use the correct fastener in the correct location. Replacement

fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service
procedure. DO NOT use paints, lubricants, or corrosion inhibitors
on fasteners or fastener joint surfaces unless specified. These

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1998-99 ENGINES 3.8L V6
coatings affect fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening sequence and
specifications when installing fasteners in order to avoid damage
to parts and systems.
1. Apply engine oil to the inside and the outside diameter of the new crankshaft rear oil
seal. Slide the new crankshaft rear oil seal over the mandrel until the back of the
crankshaft rear oil seal bottoms squarely against the collar of the Rear Crankshaft Seal
Installer (J-38196). See Fig. 15.
2. Install the crankshaft rear oil seal using the following steps:
Attach the Rear Crankshaft Seal Installer (J-38196) to the crankshaft by hand, or
tighten the attaching screws. Tighten the screws to 54 INCH lbs. (5 N.m).
Tum the I-handle of the Rear Crankshaft Seal Installer (J-38196) so that the
collar pushes the seal into the bore. Tum the handle until the collar is tight against
the case. This will ensure that the crankshaft rear oil seal is seated properly
between the crankshaft and the crankshaft rear oil seal housing.
Loosen the T-handle of the Rear Crankshaft Seal Installer (J- 38196) until the
handle comes to a stop. This will make sure that the collar will be in the proper
position for installing another new crankshaft rear oil seal.
Remove the attaching screws.
3. To install the engine flywheel, use the Flywheel Holding Tool (J-37096) in order to
prevent the crankshaft from rotating. Use NEW engine flywheel bolts. Tighten to
specification. See TORQUE SPECIFICATIONS
4. Use the Torque Angle Meter (J-36660-A) in order to rotate the engine flywheel bolts an
additional 50 degrees. Install the transaxle.

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1998-99 ENGINES 3.8L V6
J 38196
~/
G00255788
Fig. 15: Installing Crankshaft Rear Oil Seal

CRANKSHAFT REAR OIL SEAL HOUSING
CAUTION: If seal housing bore is not centered in relation to crankshaft

flange, seal may leak.
Removal
Remove transaxle. For A/T, see appropriate REMOVAL & INSTALLATION article in
TRANSMISSION SERVICING. For MIT, see appropriate article in CLUTCHES. Remove
flexplate/flywheel. Remove oil pan. See OIL PAN . Loosen seal housing bolts (bolts should
stay with housing). Remove seal housing. Remove seal from housing.
Installation
1. DO NOT install seal into housing at this time. Clean gasket surfaces of housing and
block. Install NEW gasket onto housing bolts to hold it in place. Install seal housing.
Finger-tighten bolts so housing can be aligned (centered). Ensure gasket does not
protrude beyond oil pan gasket surface.
2. Apply a thin film of engine oil to inner and outer surfaces of Seal Housing Aligner (J41349). Install seal housing aligner onto crankshaft, twisting and turning it as necessary

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1998-99 ENGINES 3.8L V6
to aid installation.
3. Lay a straightedge across cylinder block oil pan flange and seal housing flange. Using a
feeler gauge, ensure there is no more than .004" (.10 mm) step (high or low) on either
side. Rotate housing if necessary. If specification cannot be met, replace housing.
4. Apply engine oil to NEW seal. Using Seal Installer (J-38196), press seal into bore. To
complete installation, reverse removal procedure.
WATER PUMP
NOTE:

Removal & Installation ("F" & "W" Bodies)
1. Disconnect negative battery cable. Drain cooling system. Remove accessory electrical
junction block, and position aside. Loosen water pump pulley bolts. Remove drive belt.
Remove water pump pulley bolts and pulley.
2. Remove power steering pump mounting bolts, and position aside. Remove water pump
bolts, water pump and gasket. To install, reverse removal procedure using NEW gasket.
Fill and bleed cooling system. See COOLING SYSTEM BLEEDING.
Removal & Installation ("C", "G" & "H" Bodies - VIN "l ")
1. Disconnect negative battery cable. Remove A/C compressor splash shield. Loosen
water pump pulley bolts. Drain cooling system. Remove drive belts. Remove coil pack.
Remove supercharger belt tensioner.
2. Remove engine mount. Remove power steering pump. Remove engine mount bracket.
Remove idler pulley. Remove water pump pulley. Remove water pump and gasket. To
install, reverse removal procedure using NEW gasket. Fill and bleed the engine cooling
system. See COOLING SYSTEM BLEEDING .
Removal & Installation ("C" & "H" Bodies - VIN "K")
Drain cooling system. Loosen water pump pulley bolts. Remove drive belt. Remove water
pump pulley bolts and pulley. Remove water pump and gasket. To install, reverse removal
procedure using NEW gasket. Fill and bleed cooling system. See COOLING SYSTEM
BLEEDING.
Removal & Installation ("G" Body - VIN "K")
1. Drain cooling system. Remove air cleaner assembly. Remove water pump belt cover.
Remove water pump drive belt. Remove by-pass hose. Remove lower radiator hose
from thermostat housing.
2. Remove bolts from water pump cover. Remove water pump cover. Remove water
pump, pump seaL and gasket from housing using Water Pump Remover (J-38816-lA).

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1998-99 ENGINES 3.8L V6
Tum tool clockwise in order to remove water pump. Remove water pump. To install,
reverse removal procedure using NEW gasket. Fill and bleed cooling system. See
COOLING SYSTEM BLEEDING .
OIL PAN
NOTE:
Not all components may need to be removed on all models.

Remove as necessary for access and clearance.
Removal & Installation ("C", "G" & "H" Bodies)
1. Raise and support vehicle. Drain the engine oil. Remove the flywheel cover bolts and
flywheel cover. Disconnect oil level sensor harness connector. Remove the oil level
sensor. Remove the oil filter. Remove the oil pan bolts, oil pan and gasket.
2. To install, reverse removal procedure. Install oil level sensor after oil pan is installed.
Tighten all fasteners to specification. See TORQUE SPECIFICATIONS table. Fill
crankcase to proper level with appropriate oil.
Removal & Installation ("F" Body)
1. Raise and support vehicle. Drain the engine oil. On A/T models, remove the torque
converter cover. On all models, remove the engine mount through bolts. Remove the
engine mount nuts.
2. Raise the engine using Engine Support Adapters (J-28467-A) and Universal Support
Fixture (J-41044). Disconnect oil level sensor electrical connector. Remove oil level
sensor.
3. Remove the oil pan retaining bolts. Lower the rear of the oil pan while rotating
outward. Remove the oil pan.
crankcase to proper level with appropriate oil.
Removal & Installation ("W" Body)
1. Disconnect negative battery cable. Carefully disconnect the throttle body air inlet duct.
Remove upper engine torque struts. Remove serpentine belt. Install the Engine Support
Fixture (J-28467-B, J-28467-90A and J-36462-A).
2. Raise and support vehicle. Disconnect the catalytic converter pipe from the right
exhaust manifold. Remove the right front tire and wheel assembly. Remove the right
engine splash shield. Drain crankcase. Remove oil filter.
3. Disconnect A/C compressor electrical connector. Remove A/C compressor bolts, and
position aside. Disconnect the power steering oil cooler pipe brackets from the frame.
Disconnect engine mount bracket bolts from engine. Remove the engine mount lower
nuts.

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1998-99 ENGINES 3.8L V6
4. Remove torque converter cover bolts and torque converter cover. Disconnect oil level
sensor electrical connector. Remove oil level sensor.
5. Lower vehicle. Using engine support fixture, raise engine to allow access for oil pan
removal. Raise and support vehicle. Suitably support the frame. Loosen the left side
frame bolts. Remove the right side frame bolts. Lower the frame for access.
6. Remove the engine mount and the engine mount bracket. Remove the oil pan retaining
bolts. Lower and remove the oil pan.
crankcase to proper level with appropriate oil. Check and adjust wheel alignment as
necessary. See appropriate article in WHEEL ALIGNMENT.
OVERHAUL
CYLINDER HEAD
Inspection
1. Inspect cylinder head for warpage at deck and manifold surfaces. Resurface cylinder
head ifwarpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
2. After resurfacing, use a depth micrometer to measure distance from deck surface to 3
cast pads. See Fig. 16 . Replace cylinder head if dimension is less than .044" (1.12
mm). New cylinder head dimension should be .054-.066" (1.37-1.68 mm).
Valve Seats
No replacement procedure is given by manufacturer.

Valve Guides
If valve stem oil clearance is not within specification, ream valve guides for oversize valve
stem. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.
Valve Seat Correction Angles
After grinding, if seat width is too wide, use 20-degree or 70-degree stone to reduce seat
width. A 20-degree stone will lower seat. A 70-degree stone will raise seat.
Valve Spring Installed Height
1. Install valve, valve retainer and keepers. Pull upward on valve, and measure height
from top of spring seat to spring side of valve retainer. See Fig. 17 .
2. Ensure spring installed height is within specification. See VALVES & VALVE
SPRINGS table under ENGINE SPECIFICATIONS. If measurement exceeds

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1998-99 ENGINES 3.8L V6
specification, add shims under valve spring to obtain correct height.

Valve Stem Height
With valve installed in cylinder head (closed position), use steel ruler to measure distance
from spring seat to valve tip. Distance should be 1.935-1.975" (49.15-50.17 mm).
Valve Stem Oil Seals
Oversize valve stem oil seals are used for valves with oversize stems. Intake and exhaust
valve stem oil seals are different. Install oil seal according to part number and package
instructions.
Cast Pad
Cast Pad
895113233
Fig. 16: Measuring Cylinder Head Thickness

Cast Pad

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1998-99 ENGINES 3.8L V6
1-4---
Steel Ruler
Valve Retainer
G95A13235
Fig. 17: Measuring Valve Spring Installed Height

CYLINDER BLOCK ASSEMBLY
Cylinder Block
Using feeler gauge and straightedge, inspect deck surface for warpage. Replace cylinder
block if more than .010" (.25 mm) material is removed from deck surface.
Cylinder Block Flange Run out
1. With engine removed and crankshaft installed, measure cylinder block flange runout.
Mount dial indicator gauge plate flat against crankshaft flange. Place dial indicator
stem on lower left transmission bolt boss (flat area around bolt hole). Adjust dial
indicator to zero.
2. Observe and record readings obtained on all bolt hole bosses. Measurements should not
vary more than .010" (.25 mm). If readings exceed specification, check crankshaft

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1998-99 ENGINES 3.8L V6
flange runout. See CRANKSHAFT FLANGE RUNOUT.

Piston Ring Installation
Install piston rings with identification mark toward top of piston, and ring gaps properly
spaced. See Fig. 18 .
Piston & Rod Assembly
Piston can be installed on connecting rod in either direction. Install piston and connecting
rod onto crankshaft, with arrow on top of piston and/or ridge(s) on bottom of pin boss facing
toward front of engine.
Fitting Pistons
NOTE:
DO NOT machine oversize pistons, or engine balance will be

affected.
Piston diameter should be measured 1.73" (44 mm) from top of piston.
Crankshaft & Main Bearings
1. Main bearing caps are a press fit. All main caps incorporate side bolts except the rear.
Remove side bolts. Remove main cap bolts. Using Slide Hammer (J-6125-B) and Main
Bearing Cap Puller (J-41348), carefully remove caps for service. Install main bearings
and main caps. Tap bearing caps into cylinder block cavity using a brass, lead or leather
mallet before installing attaching bolts.
NOTE:
Misalignment of No. 4 main bearing cap toward transaxle can

cause interference with the flywheel-to-converter bolts.
2. DO NOT use cap bolts to pull crankshaft bearing caps into seats. Tighten NEW main
cap bolts evenly. Loosen main cap bolts one tum. Retighten bolts to 26 ft. lbs. (35
N.m). Ensure No. 4 rear main bearing cap is installed flush with rear of block.
NOTE:
DO NOT shim, scrape or file bearing inserts. DO NOT touch

bearing surface with fingers.
3. Using Torque Angle Meter (J-36660), tighten bolts an additional 50 degrees. Using
wooden mallet, carefully tap crankshaft forward and then backward to seat thrust
bearing.
Rod Bearings
1. Ensure bearing cap bolt holes and mating surfaces are clean and dry. Use connecting
rod stud protector on rod cap bolts. Install bearing inserts in connecting rod and cap.

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1998-99 ENGINES 3.8L V6
Lubricate bearings and crank pin.

2. Replace both upper and lower bearings as a set. Install bearing cap. Tighten NEW rod
bearing cap bolts to 20 ft. lbs. (27 N.m). Tighten bolts an additional 50 degrees using
Torque Angle Meter (J-36660).
Crankshaft Flange Runout
1. With engine removed and crankshaft installed, or with crankshaft mounted on "V"
blocks, measure crankshaft flange runout. Mount dial indicator and place dial indicator
stem on crankshaft flange. Adjust dial indicator to zero.
2. Mark reference point on crankshaft flange. Ensure crankshaft is thrust forward so end
float will not affect readings. Tum crankshaft 360 degrees.
3. Observe and record readings. Reading should not vary more than .002" (.05 mm).
Replace crankshaft if runout exceeds specification.
+ FRONT OF ENGINE
Oil Ring Rail~
LEFT SIDE
RIGHT SIDE
Second - - - - Compression
Ring
Oil Ring Rail
Top Compression Ring

& Oil Ring Spacer Gap
G95E13221
Fig. 18: Positioning Piston Ring Gaps

ENGINE OILING
LUBRICATION SYSTEM
The crankshaft driven, gear-type oil pump provides pressurized lubrication to the main
gallery. See Fig. 19 . Oil pump and pressure regulator valve are located in front cover.

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1998-99 ENGINES 3.8L V6
Crankcase Capacity
Engine oil capacity is approximately 4 qts. (3.7L) without filter change. After changing
filter, recheck oil level and add oil as necessary.
Normal Oil Pressure
With engine at normal operating temperature, oil pressure (with 5W-30 or IOW-30 engine
oil) should be 60 psi (4.2 kg/cm 2 ) at 1850 RPM.
11
VIEW A
11
Oil Pump
G95C13237
Fig. 19: Cross-Sectional View Of Engine Oiling System

OIL PUMP
Removal & Disassembly
Remove front cover. See FRONT COVER under REMOVAL & INSTALLATION.
Remove oil filter adapter, gasket, pressure regulator and valve from front cover. Remove
pump cover bolts, cover and gears from front cover.

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1998-99 ENGINES 3.8L V6
Inspection
1. Inspect components for damage. Measure gear end clearance. Measure housing gear
pocket depth and diameter. Measure tip clearance between gears. Measure outer gearto-housing clearance.
2. Check clearance between pressure regulator valve and bore. Replace components or
pump assembly if measurements are not within specification. See OIL PUMP
Reassembly & Installation
To reassemble, reverse disassembly procedure. Lubricate gears, and fill cavities with
petroleum jelly. Install pump cover. To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
OIL PUMP SPECIFICATIONS

Application
Gear End Clearance
Gear Tip Clearance
Housing Gear Pocket
Depth
Diameter
Outer Gear-To-Housing Clearance
Pressure Regulator Valve-To-Bore Clearance
In. (mm)
.0010-.0035 (.025-.089)
.006 (.15)
.4610-.4625 (11.7111.75)
3.508-3.512 (89.1089.20)
.008-.015 (.20-.38)
.0015-.0030 (.038-.076)
TORQUE SPECIFICATIONS
Application
Accelerator Control Cable Bracket Bolt
Balance Shaft Gear Bolt (I)
Step 1
Step 2
Balance Shaft Retainer Bolt
Camshaft Sprocket Bolt
Step 1
Step 2
Ft. Lbs. (N.m)

12 (16)
16 (22)
2
( )
Additional 70
Degrees
22 (30)
74(100)
2
( )
Additional 90
Degrees

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1998-99 ENGINES 3.8L V6
Condenser Tube Nut ("F" Body)

Connecting Rod Bolt
Step 1
Step 2
Crankshaft Pulley/Balancer Bolt
Step 1
Step 2
Cylinder Head Bolts (3)
Step 1
Step 2
Step 3 (4 Center Bolts)
Drive Belt Tensioner Bolts
EGR Valve Adapter Bolt
EGR Valve Adapter Nut
EGR Valve Heat Shield
EGR Valve Inlet Pipe Bolt ("C" & "H" Bodies)
EGR Valve Outlet Pipe
Bolt
All Except "F" Body
"F" Body
Nut
Engine Lift Bracket-To-Ignition Control Module Bolt ("F"
Body)
Engine Mount Bracket Bolt ("F" Body)
Engine Mount Nuts
All Except "F" Body
"F" Body
Lower
Upper
Evaporator Tube Bolt ("F" Body)
Exhaust Manifold Heat Shield Bolts/Nuts
All Except "W" Body
"W" Body
12 (16)
20 (27)
2
( )
Additional 50
Degrees
110 (150)
2
( )
Additional 76
Degrees
37 (50)
2
( )
Additional 120
Degrees
2
( )
Additional 30
Degrees
37 (50)
18 (25)
37 (50)
(4)
21 (29)
21
18
21
18
(29)
(25)
(29)
(25)
75 (102)
58 (78)
32 (43)
35 (4 7)
12 (16)
(5)
15 (20)

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1998-99 ENGINES 3.8L V6
Exhaust Manifold-To-Cylinder Head Bolts/Studs

"C" "G" & "H" Bodies
'
Inner Studs/Bolts
Outer Studs
"F" Body
"W" Body
Exhaust Manifold-To-Cylinder Head Nuts
All Except "F" Body
"F" Body
Exhaust Pipe-To-Exhaust Manifold Bolts/Studs
Bolts/Studs
"F" Body
"C" "G" "H" & "W" Bodies
'
'
Nuts
"W" Body
Flywheel Bolt
Step 1
Step 2
22 (30)
(5)
11 (15)
22 (30)
22 (30)
13(18)
26 (35)
18 (25)
26 (35)
11 (15)
2
( )
Frame-To-Body Bolts ("W" Body)

Front Cover Bolt
Step 1
Step 2
Fuel Feed & Return Line Fitting
Generator Bolts
"C" Body
"F" Body
Front Inboard Bolt & Rear Bolt
Front Outboard Bolt
"G" Body
Except Rear Brace Bolts (VIN "l ") & Lower BracketTo-Block Bolts (VIN "K")
Lower Bracket-To-Block Bolts (VIN "K")
Rear Brace Bolts (VIN "l ")
"H" Body
Except Rear Brace Bolts
Rear Brace Bolts
Additional 50
Degrees
133 (180)
( 6)
2
( )
15 (20)
Additional 40
Degrees
22 (30)
37 (50)
22 (30)
37 (50)
37 (50)
28 (38)
22 (30)
37 (50)
22 (30)

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1998-99 ENGINES 3.8L V6
"W" Body
(7)
Generator Brace-To-Intake Manifold Bolts ("F" Body)

Generator Positive Cable Nut
Heated Oxygen Sensor
Ignition Control Module Nuts
All Except "F" Body
18 (25)
15 (20)
31 (42)
"F" Body
Intake Manifold Bolts
VIN"l"
Lower
22 (30)
Upper (Supercharger)
VIN"K"
Lower
(8)
(l) (9) 11 (15)
17 (23)
(1) (10) 11 (15)
Upper ("C", "G", "H" & "W" Bodies)
(11)
Upper ("F" Body)
(12)
Main Bearing Cap Bolt

Step 1
Step 2
Oil Cooler Adapter Connector
Oil Cooler Line-To-Radiator ("F" Body)
Oil Filter Adapter-To-Front Cover Bolt
'
"F" & "W" Bodies
Step 1
Step 2
Oil Level Sensor
Oil Pan Bolt
30 (40)
(2) Additional 110
Degrees
37 (50)
20 (27)
22 (30)
11 (15)
2
( ) Additional 50
Degrees
15 (20)
(l) 10 (14)
Oil Screen-To-Block Bolt

Power Steering Pump Mounting Nuts
11 (15)
23 (30)
Rocker Arm Bolt (l)

Step 1
Step 2
11 (15)
(2) Additional 90
Degrees
Side Main Bearing Cap Bolt

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1998-99 ENGINES 3.8L V6
Step 1
Step 2
Spark Plugs
Supercharger-To-Intake Manifold Bolt (VIN 1)
Thermostat Housing Bolts
All Except "F" Body
"F" Body
Timing Chain Damper Bolt (Special Bolt)
Valve Lifter Guide Bolt
Water Pump Bolt
Step 1
Step 2
Wheel Lug Nuts
Fuel Rail Retaining Bolts/Nuts
All Except "F" Body
VIN"K"
VIN"l"
"F" Body
Idle Air Control Valve Screws
Ignition Coil-To-Control Module Screws
Ignition Control Module Harness Connector Bolt
Intake Manifold Vacuum Source Fitting Screws ("F" Body)
Oil Pump Cover Screw
Rocker Arm Cover Bolt
Throttle Body Nuts/Bolts
Throttle Body Support Bracket Bolts
Torque Converter Cover Bolts
'
"F" Body
"W" Body
(1) Apply thread locking compound to bolt(s).
(2) See Fig. 20 .
(3) Tighten bolts in sequence. See Fig. 6 .
11 (15)
(2) Additional 45
Degrees
20 (27)
17 (23)
15
20
16
22
(20)
(27)
(22)
(30)
11 (15)
2
( ) Additional 80
Degrees
104 (140)
INCH Lbs. (N.m)
89 (10)
(13)
75 (8.5)
27 (3.0)
40 (4.5)
22 (2.5)
89 (10)
97 (11)
(l) 88 (10)
89 (10)
89 (10)
115 (13)
75 (8.5)
89 (10)

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1998-99 ENGINES 3.8L V6
(4) Information is not available from manufacturer.

(5) Tighten to 89 INCH lbs. (10 N.m).
(6) Apply thread sealant to bolt(s).
(7) Tighten bolts in sequence to 37 ft. lbs. (50 N.m). First, tighten the inboard
generator bolt. Second, tighten the generator stud. Last, tighten the generator rear
bracket bolt.
(8) Tighten nuts to 70 INCH lbs. (8 N.m).
(9) Tighten bolts in sequence. See Fig. 5 .
(10) Tighten bolts in sequence. See Fig. 4 or Fig. 5 .
(11) Tighten bolts in sequence to 89 INCH lbs. (10 N.m). See Fig. 3 .
(12) Tighten bolts No. 1-10 in sequence to 11 ft. lbs. (15 N.m). See Fig. 2 . Tighten
side bolts No. 12 and 13 to 22 ft. lbs. (30 N.m).

(13) Tighten fuel rail retaining bolts to 89 INCH lbs. (10 N.m). Tighten fuel rail
retaining stud to 18 ft. lbs. (25 N.m).

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1998-99 ENGINES 3.8L V6
360
o0
3~
120
150
180
G00215026
Fig. 20: View Of Torque Angles

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Displacement
Bore
Stroke
Compression Ratio (VINK)
Compression Ratio (VIN 1)
Fuel System
Specification
231 Cu. In. (3.8L)
3.80" (96.5 mm)
3.40" (86.4 mm)
9.4:1
8.5:1
SFI

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1998-99 ENGINES 3.8L V6
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application
In. (mm)
Crankshaft End Play
.003-.011 (.08-.28)
Main Bearings
Journal Diameter
2.4988-2.4998 (63.47063.495)
Journal Out-Of-Round
1998
.0003 (.008)
1999
.0025(.0066)
Journal Taper
.0003 (.008)
Oil Clearance (1998)
.0007-.0016 (.0178Journal No. 1
.0406)
Journals No. 2 & 3
.0010-.0020 (.0254.0508)
Journal No. 4
.0009-.0018 (.0229.0457)
Oil Clearance (1999)
.0007-.0016 (.0178Journal No. 1
.0406)
Journals No. 2, 3 & 4
.0009-.0018 (.0229.0457)
Connecting Rod Bearings
Journal Diameter
2.2487-2.2499 (57.11757.147)
Journal Out-Of-Round
1998
.0003(.0076)
1999
.0002 (.005)
Journal Taper
.00030 (.0076)
1998
1999
.00035 (.0089)
.0005-.0026 (.0127-.0660)
Oil Clearance
CONNECTING RODS
Application
Maximum Bend
Maximum Twist
Side Play
Bend or twist measured over total length.
In. (mm)
(l) .005 (.13)
(l) .005 (.13)
.0040-.0200 (.102-.508)

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1998-99 ENGINES 3.8L V6
(1)
PISTONS, PINS & RINGS

Application
Piston Clearance (l)

Used Piston (1999)
VIN 1
All Others
New Piston
VIN 1 (1999)
All Others
Pins
Diameter
VIN 1 (1999)
All Others
Piston Fit
VIN 1 (1999)
All Others
Rod Fit
VIN 1 (1999)
All Others
Rings
No. 1
End Gap
Side Clearance
No.2
End Gap
Side Clearance
No. 3 (Oil)
End Gap
Side Clearance
(1) Measure 1.5" (39 mm) form top of engine block.
CYLINDER BLOCK
Application
Cylinder Bore
Diameter
In. (mm)
.0008-.0039 (.0193-.0997)
.0020-.0036 (.050-.091)
.0008-.0039 (.0193-.0997)
.0004-.0020 (.010-.051)
.9053-.9055 (22.995-23.000)
.8659-.8661 (21.995-22.000)
.00026-.00061 (.0065-.0155)
.00008-.00051 (.0020-.0130)
.00029-.00089 (.0073-.0225)
.00030-.00090 (.0066-.0217)
.010-.018 (.25-.46)
.0013-.0031 (.033-.079)
.023-.033 (.58-.84)
.0013-.0031 (.033-.079)
.010-.030 (.25-.76)
.0009-.0079 (.023-.201)
In. (mm)
3.80 (96.5)

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1998-99 ENGINES 3.8L V6
Maximum Taper
Maximum Out-Of-Round
.001 (.0254)
.001 (.0254)
VALVES & VALVE SPRINGS

Application
Valves
Face Angle
Minimum Margin
Installed Height
Specification
45
.025" (.64 mm)
1.935-1.975" (49.15-50.17
mm)
Valve Springs
Free Length
Installed Height
1.960" (49.78 mm)

1.690-1. 720" (42.93-44.45
mm)
Lbs. @In. (kg@mm)
Pressure
Valve Closed
Valve Open
75 @ 1.72 (34@ 43.7)

228@ 1.277 (104@
32.4)
CYLINDER HEAD
Application
Maximum Warpage
Valve Seats
Intake Valve
Seat Angle
Seat Width
Seat Runout (Maximum)
Exhaust Valve
Seat Angle
Seat Width
Seat Runout (Maximum)
Valve Guide Oil Clearance
Specification
.010" (.25 mm)
45
.060-.080" (1.52-2.03 mm)
.002" (.05 mm)
45
.090-.110" (2.29-2.79 mm)
.002" (.05 mm)
.0015-.0035" (.038-.089 mm)
CAMSHAFT
Application
Joumal Diameter
Lobe Lift
Intake
In. (mm)
1.8448-1.8762 (46.858-47 .655)
.2580 (6.55)

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1998-99 ENGINES 3.8L V6
Exhaust
Oil Clearance
.255 (6.48)
.0016-.0047 (.041-.119)

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1998-99 TRANSMISSION SERVICING Automatic Transmission - Cars - Except Metro & Prizm
1998-99 TRANSMISSION SERVICING

Automatic Transmission - Cars - Except Metro & Prizm
APPLICATION & IDENTIFICATION

BODY CODE IDENTIFICATION
Body Code
Model
"C"
Park Avenue
"E"
Eldorado
"F"
Camaro & Firebird
"G"
Aurora & Riviera
"H"
Bonneville, Eighty Eight, LeSabre, LSS & Regency
"J"
Cavalier & Sunfire
"K"
De Ville & Seville
"N"
Achieva, Alero, Cutlass, Grand Am, Malibu & Skylark
"V"
Catera
"W"
Century, Grand Prix, Intrigue, Lumina, Monte Carlo &
Regal
"Y"
Corvette
"Z"
Saturn
AUTOMATIC TRANSMISSION & TRANSAXLE IDENTIFICATION
Vehicle Application
Trans. Model (RPO Code)
Buick
Century
4T60E (Ml3)
Le Sabre
4T65E (MN3 Or Ml5)
Park Avenue
4 T65E (MN3 Or MN7)
Regal
4T65E (Ml5 Or MN7)
Riviera
4T65E (MN7)
Skylark
4T60E (MN13)
Cadillac
4L30E (ML4)
Catera
De Ville
4T80E (MHI)
Eldorado
4T80E (MHI)
Seville
4T80E (MHI)
Chevrolet
Camaro
4L60E (M30)
Cavalier
3T40 (MD9) Or 4T40E (MN4)
4L60E (M30)
Corvette

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Lumina
3.IL
3.8L
Malibu
Monte Carlo
3.IL
3.8L
Oldsmobile
Achieva
Alero
2.4L
3.4L
Aurora
Cutlass
Eighty Eight
Intrigue
3.5L
3.8L
LSS
Regency
Pontiac
Bonneville
Firebird
Grand Am
2.4L
3.IL
3.4L
Grand Prix
3.IL
3.8L
Sunfire
2.2L
2.4L
Saturn
OIL PAN GASKET IDENTIFICATION
4T60E (Ml3)
4T65E (Ml5)
4T40E (MN4)
4T60E (Ml3)
4T65E (Ml5)
4T40E (MN4) Or 4T60E
(Ml3)
4T40E (MN4)
4T45E (MN5)
4T80E (MHI)
4T40E (MN4)
4T65E (Ml5 Or MN3)
4T65E (MN3)
4T65E (Ml5)
4T65E (MN7 Or MN3)
4T65E (Ml5)
4T65E (MN3, MN7 Or Ml5)
4L60E (M30)
4T40E (MN4) Or 4T60E
(Ml3)
4T60E (Ml3)
4T45E (MN5)
4T60E (Ml3)
4T65E (MN7 Or Ml5)
3T40 (MD9) Or 4T40E
(MN4)
4T40E (MN4)
MP6&MP7

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G94H32570
Fig. 1: Identifying Saturn MP6/MP7 Oil Pan Gasket

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895113696
Fig. 2: Identifying Hydra-Matic 3T40 Oil Pan Gasket

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G97F28923
Fig. 3: Identifying Hydra-Matic 4L30-E Oil Pan Gasket

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G95J13697

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G91B13525

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G95H13695
Fig. 6: Identifying Hydra-Matic 4T40-E & 4T45-E Oil Pan Gasket

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G95A13698
Fig. 7: Identifying Hydra-Matic 4T60-E & 4T65-E Oil Pan Gasket

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G94J32572
Fig. 8: Identifying Hydra-Matic 4T80-E Oil Pan Gasket
LUBRICATION
SERVICE INTERVALS
NOTE:
Driver Information Display CHANGE TRANS FLUID message may

be displayed on some models. If CHANGE TRANS FLUID
message is displayed, see DRAINING & REFILLING procedure. To
reset message, press and hold OFF and REAR DEFOG buttons
until TRANS FLUID RESET appears in Information Center (5-20
seconds).
Except Saturn
Check transmission fluid level at every engine oil change. Transmission fluid should not be
changed under normal operating conditions. Under continuous extreme operating conditions
(trailer towing, heavy city traffic with ambient temperature more than 90F (32C) or
delivery service), fluid and filter should be changed every 50,000 miles.
Saturn

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Check fluid at every engine oil change. Under normal conditions, replace fluid and filter
every 30,000 miles.
CHECKING FLUID LEVEL
4L30-E & 4L60-E (RWD)
1. Fluid level must be check at temperature of 113-185F (45-85C). Start engine and
place gear selector in Park. Raise vehicle on hoist. With engine running at idle, remove
fill plug from side of transmission pan and check fluid level.
2. Fluid should be at lower level of fill plug. Adjust fluid as necessary. Use an oil suction
gun to add fluid. If fluid level is low add fluid in one pint increments. Install filler plug
and tighten to specification. Lower vehicle.
4T40-E & 4T45-E
1. Fluid level must be checked at temperature of 104F (40C). To obtain proper

temperature, perform the following:
Idle vehicle for 3-5 minutes.
Shift into each gear position, holding in each position for 3 seconds.
2. Place gear selector in Park. Raise and support vehicle. Place oil drain pan below oil
check plug. Oil check plug is located in center of transaxle above pan rail, on torque
converter side. See Fig. 9. Remove oil check plug.

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Fill/Vent
Cap
Torque
Converter
Output
Speed
Sensor
Oil Check Plug

G95B13699
Fig. 9: Locating 4T40-E & 4T45-E Oil Check Plug

3. Oil level should be at bottom of oil check plug hole. If fluid does not drain from hole,
add fluid until fluid starts to pour from hole. Tighten oil check plug to 10 ft. lbs. (14
N.m).
CAUTION: DO NOT overfill transmission. When transmission is hot,

one pint of fluid will raise fluid level from ADD 1 PT. or .SL
mark to FULL HOT mark on dipstick.
All Others
1. Start engine. Operate vehicle for at least 15 minutes or until operating temperature is
reached. With engine at curb idle and vehicle on level ground, move gear selector lever
through all ranges, ending in Park.
2. Remove transmission dipstick, wipe clean and fully reinsert into filler tube. Remove

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dipstick again, and inspect fluid level. Fluid level should be between ADD 1 PT. or .5L
mark and FULL HOT mark on dipstick.
CAUTION: If vehicle has been driven for an extended period of time at

high speeds, in city traffic, in hot weather or if vehicle has
been pulling a trailer, an accurate fluid level reading cannot
be made until vehicle has been parked and ATF is allowed
to cool about 30 minutes.
RECOMMENDED FLUID
Use only Dexron-III Automatic Transmission Fluid (ATF).

FLUID CAPACITIES
FLUID CAPACITIES (l)

Drain & Refill(2)
Qts. (L)
4.0 (3.8)
7.0 (6.6)
Application
3T40
4L30-E
4L60-E
Corvette
5.0 (4.7)
Except Corvette
5.0 (4.7)
4T40-E & 4T45-E
7.4 (7.0)
4T60-E & 4T65-E
7.4 (7.0)
4T80-E
11.0 (10.6)
Saturn
4.2 (4.0)
(1) Fluid capacities listed are approximate. Always fill to FULL mark.
Overhaul Qts.
(L)
7.0 (6.6)
(3)
10.8 (10.2)
11.0 (10.6)
12.9 (12.2)
10.0 (9.5)
15.0 (14.2)
7.4 (7.0)
(2) Drain and refill capacity does not include torque converter.
(3) Transmission does not have a dipstick. Fill to bottom of fill plug.
DRAINING & REFILLING
NOTE:
If oil pan bolts are equipped with conical washers, DO NOT reuse
bolts if conical washers have become reversed. See Fig. 10.

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Conical
Washer
MUST NOT
REUSE
REUSE
G95E13700
Fig. 10: Identifying Conical Washers

1. Raise vehicle, and place large drain pan under transmission oil pan. Remove
transmission oil pan front and side bolts only. Loosen rear bolts about 4 turns each.
2. Carefully pry pan loose using screwdriver. Allow fluid to drain. Remove remaining
bolts, and remove oil pan. Discard old pan gasket. Remove filter and "O" ring or
sleeve-type seal. Remove any remaining gasket material on transmission case.
3. Thoroughly clean pan, magnet and screen (if metal) with solvent, and then dry using
compressed air. Replace paper filter (if equipped). Install NEW "O" ring on pick-up
tube or NEW sleeve into pick-up tube recess. Lubricate with clean oil before
installation.
4. Install filter assembly into pick-up tube recess. Install oil pan using NEW gasket, and
tighten pan bolts to specification. See TORQUE SPECIFICATIONS. Add required
amount of fluid to transmission through filler tube.
5. Start engine with gear selector lever in Park and parking brake applied. Check fluid
level. See CHECKING FLUID LEVEL. Add fluid if necessary. DO NOT overfill.

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ADJUSTMENTS
PARK LOCK CABLE (FLOOR SHIFT)
WARNING: When battery is disconnected, vehicle computer and

memory systems may lose memory data. Driveability
problems may exist until computer systems have
completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.
NOTE:
Vehicles with column shift do not use a park/lock control cable.

On all vehicles, with transmission range selector lever in Park
position and ignition switch in LOCK position, ensure
transmission range selector cannot be moved to any other
position. Ignition key should be removable.
"F" & "N" Bodies
1. With gear selector lever in Park and ignition switch in LOCK position, gear selector
lever should not be able to be moved to other gear positions and ignition key should be
removable from lock cylinder.
2. With ignition switch in RUN position and gear selector lever in Neutral, ensure ignition
switch cannot be turned to LOCK position. If system does not perform as described,
unlock park lock cable adjuster (button up). See Fig. 11. Move cable connector nose
rearward until key can be removed from ignition. Lock cable adjuster (button down).

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Steering
Column
Cable Assembly
VIEW 11 A 11
Gear Selector Control
Lock Button
G95B13707
Fig. 11: Adjusting Park Lock Cable ("F" & "N" Bodies - Floor Shift)
"J" Body

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1. With ignition switch in RUN position and gear selector lever in Neutral, ensure ignition
switch cannot be turned to LOCK position.
2. With gear selector lever in Park and ignition switch in LOCK position, gear selector
lever should not be able to be moved to other gear positions and ignition key should be
removable from lock cylinder.
3. If system does not perform as described, dislodge park/lock cable housing lock at
ignition switch. Adjust outer cable housing to position White plastic collar in park/lock
housing. See Fig. 12.
4. Ensure no gap is present between metal terminal stop at end of cable and White plastic
collar. White plastic collar should be flush or less than .040" (1.0 mm) recessed in
park/lock housing. Hold cable in position, and seat park/lock cable housing lock. Retest
park/lock cable operation.

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Correct Adjustment
With Key Removed
& Shifter In Park
Dislodge
Lock Here
Metal
Terminal
Stop ----.-~==;.
Cable Housing
Park/Lock
Housing
White Plastic
Collar
Cable
Housing
95C13708
Fig. 12: Adjusting Park Lock Cable ("J" Body - Floor Shift)
Saturn
1. Place gear selector in Park, and remove key. Remove cup holder/ashtray assembly. Lift
lock tab on park lock cable end. See Fig. 13. Depress gear selector shift knob button
quickly 3 times to set starting position of cable. Using a sharp pencil, mark starting
position on slider. See Fig. 13.

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....
Lift
--...,
Here~.,.-J
Lock Tab
Mark Slider Here
i i
-----
Slider
Park
Lock
Cable
Shifter
Base
G95B13715
Fig. 13: Locating Park Lock Cable Components (Saturn)

NOTE:
Adjustment may move when lock tab is pushed. Proper

operation must be verified prior to reassembly.
2. Using a feeler gauge for adjustment, move park lock cable towards shifter
base .049" (1.25 mm). Push lock tab of shift lock cable end to set position.
3. With ignition off and shifter in Park, attempt to shift lever out of Park. Lever should not
move. Tum ignition on. Shift lever should be allowed out of Park. Place shift lever in
any position except Park and tum ignition off. Ignition key should not be removable.
Attempt to place shift lever in Park. Lever should go into Park, and ignition key should
be able to be removed.
4. If park lock cable fails any test, readjust cable. Check gearshift cable adjustment. See
SHIFT CABLE (FWD). Install cup holder/ashtray assembly.
PARK NEUTRAL POSITION (PNP) SWITCH
NOTE:
PNP switch may also be called Transmission Range (TR) switch,

and was also previously known as neutral safety switch. Adjust

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switch so engine will start in Park or Neutral only.

FWD (Saturn)
Place gear selector in Drive. Using an ohmmeter, check for continuity across switch
terminals. If continuity does not exist, loosen switch retaining bolts and rotate switch to
obtain continuity. Tighten switch retaining bolts to 12 ft. lbs. (16 N.m) and recheck
continuity.
FWD (Except Saturn)
1. Neutral safety switches come in 2 different types. See Fig. 14. Ensure shift cable is
adjusted. To adjust switch, place gear selector lever in Neutral.
2. Place transaxle lever in Neutral detent. Loosen switch attaching screws. Rotate switch
on shifter assembly to align adjustment hole with carrier tang hole.
3. Insert a .094" (2.4 mm) wire gauge about 5/8" (16 mm) into switch holes. Tighten
attaching screws. Remove wire gauge. New switches may have a plastic pin installed in
hole. Plastic pin is designed to shear off during initial shift lever operation.
Attaching
Screws
Neutral
Safety Switch
~~I
Adjustment
Hole
Wire Gauge
(Or Drill Bit)
G95D13709
Fig. 14: Adjusting Park Neutral Position (PNP) Switches (FWD)

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RWD (Camaro, Corvette & Firebird)
1. Disconnect negative battery cable. Remove gear selector knob and center console
cover. Place gear selector lever in Neutral. If old switch is being adjusted, go to next
step. IfNEW switch is being installed, go to step 4.
2. Align tang on switch with tang slot on shift control. See Fig. 15. Loosen switch
mounting nuts. Rotate switch to align service adjustment hole with carrier tang hole.
3. Insert a .092" (2.34 mm) wire gauge into adjustment hole in top of switch. Rotate
switch until pin drops to depth of .59" (15 mm). Tighten mounting nuts to 27 INCH lbs.
(3 N.m). Vehicle should only start in Park or Neutral.
4. IfNEW switch if being installed, insert switch tang in slot on shift control. Tighten
mounting nuts to 27 INCH lbs. (3 N.m).
5. Ensure gear selector lever is in Neutral if holes DO NOT align with shift control. DO
NOT rotate switch. Switch is pinned in Neutral.
NOTE:
If NEW switch is rotated and pin breaks during installation,

use adjustment procedure in step 2.
6. If holes align with shift control, move gear selector lever out of Neutral to shear plastic
pm.

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Neutral
Safety Switch
G95G13710
Fig. 15: Adjusting Park Neutral Position (PNP) Switches ("Y" Body Shown; "F" Body
Is Similar)
RWD (Catera)
1. Apply parking brake. Place gear selector to Neutral. Raise and support vehicle. Remove
cover from selector lever position switch. Remove selector lever from switch.
Disconnect harness connector from switch.
2. Connect ohmmeter between switch terminals "E" and "H". Loosen selector switch-totransmission bolts. Rotate switch slightly in both directions to determine range of
electrical contact (about 5 degrees).
3. Position switch in middle of contact range. Tighten hold-down bolts to 106 INCH lbs.
(12 N.m). Install linkages and wiring harness. Tighten selector lever shaft nut to 71
INCH lbs. (71 N.m).
SHIFT CABLE (FWD)
WARNING: Adjust shift cable so engine will start in Park or Neutral

only. Misadjusted shift linkage could cause clutch and/or

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band failure in transmission.

NOTE:
Most FWD vehicles are equipped with a self-adjusting shift

cable.
Saturn
1. Place gear selector in Park. Raise and support vehicle. Disconnect cable assembly at
transaxle control lever. Ensure transaxle control lever is turned fully clockwise, in Park.
2. Using a small screwdriver, pry up cable adjuster lock tab. See Fig. 16. Reconnect cable
assembly to transaxle control lever. Ensure cable housing moves freely inside adjuster
housing. Move cable housing back and forth, and note amount of end play.
3. Adjust cable by moving cable housing 1/2 the amount of total end play. Press lock tab
down and ensure cable housing is secure. Check park lock cable adjustment. See
PARK LOCK CABLE (FLOOR SHIFT).
Lock Tab
Pry Up Here
G95113712
Fig. 16: Locating Gearshift Cable Lock Tab (Saturn)

Except Saturn
Place gear selector lever in Neutral. Lift or press lock button on cable adjuster at transaxle
mounting bracket. See Fig. 17 and Fig. 18 . Place transaxle lever in Neutral detent. Push
down or release lock button.

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PRESS OR
RELEASE BUTTON
Shift Cable
G95H13703
Fig. 17: Adjusting Shift Cable (" J" & "N" Bodies)

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''
'
Shift
Cable
~.,__-Transaxle
Lever
LIFT OR
PUSH DOWN
BUTTON
'-C:::=
---
G95113704
Fig. 18: Adjusting Shift Cable (Except "J" & "N" Bodies)
SHIFT CABLE (RWD)
WARNING: Adjust shift cable so engine will start in Park or Neutral

CAUTION: To prevent transaxle damage on Camaro, Corvette and
Firebird, hold lever out of Park when tightening cable

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adjusting nut.
Camaro & Firebird
Place gear selector lever in Neutral. Raise and support vehicle. Loosen cable adjusting nut at
transmission lever. See Fig. 19. Ensure shift shaft lever is in Neutral by rotating lever
clockwise to Park detent, and then counterclockwise 2 detents to Neutral. Tighten nut (DO
NOT tighten nut with lever in Park).
Gear Selector Lever
Cable
Adjusting Nut--___,~
95J13705
Fig. 19: Adjusting Shift Cable (Camaro & Firebird)

Corvette
1. Place gear selector lever in Neutral. Raise and support vehicle. Using a flat-blade
screwdriver, pry up to release shift cable adjustment lock. See Fig. 20.
2. Ensure gear selector lever and transmission shift lever are in Neutral. Press on shift
cable lock to secure cable adjustment in place. Lower vehicle and check gearshift lever
operation.

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Shift Cable
PNP Switch
Shift Cable
Adjustment
Lock
G98B07120
Fig. 20: Adjusting Shift Cable (Corvette)

SHIFT LINKAGE ROD (RWD)
WARNING: Adjust shift linkage so engine will start in Park or Neutral

Cater a
1. Position shift control lever in Park. Raise and support vehicle. Loosen shift linkage
adjuster bolt from underneath vehicle.
2. Hold selector lever on transmission against rear stop to eliminate play. Tighten shift
lever rod adiustment bolt to 71 INCH lbs. (8 N.m).

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STOPLIGHT SWITCH
Except Saturn
Ensure brake pedal is fully released. Adjust switch until switch plunger just touches brake
pedal lever.
Saturn
1. Loosen stoplight switch mounting nut enough to allow switch to move in adjustment
slot. Install Adjustment Gauge (SA9303BR) between switch and actuator pad on brake
pedal arm, ensuring switch plunger protrudes through slot in gauge.
2. Pull up on brake pedal with moderate force while pushing switch forward against
gauge.
NOTE:
It is important to hold switch perpendicular to actuator pad

(maintaining alignment) while tightening mounting nut.
3. Tighten switch mounting nut. Release brake pedal. With pedal released and adjustment
gauge still in position, ensure gauge will swing freely. If gauge does not swing freely,
repeat steps 1-3 .
4. With gauge still in position, pull up on brake pedal with very light force and tap gauge
side to side. If gauge swings freely, repeat steps 1-4 .
5. Inspect switch plunger. If .040" (1.0 mm) or less of plunger is visible between switch
and switch actuator pad, switch is correctly adjusted. Height of rounded crown of
plunger is equivalent to .040" (1.0 mm). If more than .040" (1.0 mm) of plunger is
visible, repeat steps 1-5 .
THROTTLE VALVE (T.V.) CABLE
NOTE:
T.V. cable is not used on electronically controlled

models.
All Models (If Equipped)
1. Tum ignition off. Press and hold metal readjust tab on cable adjuster at cable support
bracket on engine. See Fig. 21. Pull cable housing away from throttle lever until
housing stops and is completely against adjuster. Release readjust tab.
2. Manually rotate throttle lever to its full throttle position. Ensure slider moves (ratchets)
toward lever when lever is rotated to its full throttle position. Check cable for sticking
and binding.

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Readjust Tab
l
~i
+ r~~~~TLE==~~ ~ G95G13702
V
Slider
READJUST
DIRECTION ..
Detent
Cable
Fig. 21: Adjusting TV Cable

Transmission
Oil Pan Bolts
3T40, 4T40-E & 4T45-E
4L30-E
4L60-E
Corvette
Except Corvette
4T60-E
4T65-E
4T80-E
Saturn
Oil Fill Plug
4L30-E (Catera)
4L60-E (Corvette)
INCH Lbs. (N.m)

106 (12)
92 (11)
97
144
98
97
106
88
(11)
(16)
(11)
(11)
(12)
(10)
33 (45)
22 (30)
Document ID: 393855
1999 Pontiac Bonneville
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Brakes | Antilock Brake System |
Specifications | Document ID: 393855
Fastener Tightening Specifications

Specification
Application
Metric
English
BPMV Bracket to frame Bolt/Screw
24 Nm
18 lb ft
Brake Pipe Fittings At BPMV
16 Nm
12 lb ft
EBCM/EBTCM to BPMV Bolts
6 Nm
53 lb in
EBCM/EBTCM to BPMV Center Bracket Bolt
14 Nm
10 lb ft
EBCM/EBTCM Insulator Bracket Nuts
10 Nm
89 lb in
2011 General Motors Corporation. All rights reserved.
http://localhost:9001/si/showDoc.do?docSyskey=393855&pubCellSyskey=940&pubObjSys... 2/7/2011
Document ID: 386924
Page 1 of 1
Schematic and Routing Diagrams | Document ID: 386924
Cell 44: PWR, GND, and Stoplamp/BTSI Switch
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2/7/2011
Document ID: 386928
Page 1 of 1
Cell 44: ABS/TCS Switch, UART, PCM, and Traction Control

Switch
2/7/2011
Document ID: 386933
Page 1 of 1
Cell 44: Wheel Speed Sensors and Variable Power Steering

Actuator
2/7/2011
Document ID: 386934
Page 1 of 1
Cell 44: Buick Indicators
2/7/2011
Document ID: 386937
Page 1 of 1
Cell 44: Pontiac Indicators
2/7/2011
Document ID: 386938
Page 1 of 1
Cell 44: Oldsmobile Indicators
2/7/2011
Document ID: 343349
Page 1 of 1
Component Locator | Document ID: 343349
Passenger Compartment, Below the Center of the Instrument

Panel
(1) Lamp Monitor Control Module

(2) S259
(3) S258
(4) S236
(5) S232
(6) S235
(7) To C200
(8) Stoplamp/BTSI Switch
(9) ABS/TCC Switch
(10) S231
(11) S228
(12) S230
(13) S296
(2)
2/7/2011
Document ID: 343377
Page 1 of 1
Passenger Compartment, Below the Right Corner of the IP
(1) Brake Lamp Driver Module

(2) Perimeter Lighting Relay
(3) Body Control Module (MALL)
(4) S274
(5) S247
(6) S267
2/7/2011
Document ID: 228439
Page 1 of 1
Engine Compartment, Lower Left Corner
(1) Brake Pressure Modulator Valve (BPMV) Ground

(2) Brake Pressure Modulator Valve (BPMV)
(3) Electronic Brake And Traction Control Module (EBCM/EBTCM)
(4) C119
2/7/2011
Document ID: 343303
Page 1 of 1
Wheel Opening, Left Front
(1) C120 (LH) C121 (RH)

(2) LH Front Wheel Speed Sensor (RH Similar)
(3) LH Front Disc Brake Rotor (RH Similar)
2/7/2011
Document ID: 318664
Page 1 of 1
Under the Rear of the Vehicle
(1) RH Rear Wheel Speed Sensor (LH Similar)

(2) C415
(3) Automatic Level Control Sensor
2/7/2011
Document ID: 393866
Page 1 of 6
Antilock Brake System Connector End Views

Table 1:
Brake Lamp Driver Module
Table 2:
Electronic Brake (and Traction) Control Module (EBCM/EBTCM) Connector
Table 3:
LH Front Wheel Speed Sensor
Table 4:
LH Rear Wheel Speed Sensor
Table 5:
RH Front Wheel Speed Sensor
Table 6:
RH Rear Wheel Speed Sensor
Table 7:
Traction Control Disable Switch
ABS/TCC Switch
Connector Part Information
12033704
4-Way F Metri-Pack 280 Series (BLK)
Pin
Wire Color
Circuit No.
Function
BRN
241
Fused Output - IGN3
PPL
420
Brake Pedal Switch Output - TCC
TAN
848
Brake Pedal Switch Output - ABS
BLK
1250
Ground
Brake Lamp Driver Module
Document ID: 393866
Connector Part
Information
Page 2 of 6
12015410
6-Way PC Edgeboard - STD (GRN)
Pin
Wire Color
Circuit
No.
DK BLU
1660
PNK
39
WHT
852
BLK
1250
LT GRN/BLK
875
PPL/WHT
1572
Function
Traction Controls System Active Indicator Lamp
Output
Fuse Output - Ign 1
ABS Signal - ABS Failure
Ground
ABS Indicator Lamp Driver Module Output
Traction Control System Indicator Lamp Output Failure
Electronic Brake (and Traction) Control Module

(EBCM/EBTCM) Connector
12160529 (C1)
Connector Part
Information
6 Way Metri-Pack 280 Series (BLK)

12129228 (C2)
Document ID: 393866
Page 3 of 6
32 Way Micro-Pack 100 Series (NAT)

Pin
Wire Color
Circuit
No.
BRN
641
BLK
1050
Ground
GRY
1787
Feed Motor (High Effort)
RED
342
Fused Output (Bat)
RED
642
Fused Output (Bat)
WHT
345
Feed Motor (Low Effort)
ORN/BLK
463
Traction Control System Signal (Torque Desired)
BRN/WHT
1571
WHT
17
Stoplamp Switch Output (Oldsmobile, Buick)
LT BLU
20
Stoplamp Feed (Pontiac)
TAN
848
5-6
--
--
PPL/WHT
1572
LT BLU
830
LF Speed Sensor Signal
DK GRN
872
RF Speed Sensor Signal
10
BLK
884
LR Speed Sensor Signal
11
BRN
882
RR Speed Sensor Signal
12
--
--
13
WHT
852
ABS Signal (Failure)
14
TAN/BLK
464
Traction Control System Signal (Torque

Delivered)
15
TAN
800
UART Serial Data Signal
16
BLK
--
Vent Tube
17-23
--
--
Not Used
24
YEL
873
LF Speed Sensor Return
25
TAN
833
RF Speed Sensor Return
26
RED
885
LR Speed Sensor Return
27
WHT
883
RR Speed Sensor Return
28-29
--
--
30
TAN
800
31-32
--
--
Function
Fused Output - IGN
Traction Control System Switch Signal
Brake Pedal Switch Signal (ABS)

Not Used
Traction Control System Lamp Output (Failure)
Not Used
Not Used
Not Used
LH Front Wheel Speed Sensor
Document ID: 393866
Page 4 of 6
12052638
2-Way F Metri-Pak 150 Series (LT GRY)
Pin
Wire Color
Circuit No.
Function
WHT
873
Wheel Speed Sensor Return Left Front
BLK
830
Wheel Speed Sensor Signal Left Front
LH Rear Wheel Speed Sensor
12124823
2-Way F Metri-Pak 150 Series (MD GRY)
Pin
Wire Color
Circuit No.
Function
WHT
885
Wheel Speed Sensor Return Left Rear
BLK
884
Wheel Speed Sensor Signal Left Rear
RH Front Wheel Speed Sensor
Document ID: 393866
Page 5 of 6
12052638
2 Way F Metri-Pack 150 Series (LT GRY)
Pin
Wire Color
Circuit No.
Function
WHT
833
Wheel Speed Sensor Return - Right Front
BLK
872
Wheel Speed Sensor Signal - Right Front
RH Rear Wheel Speed Sensor
12124823
2-Way F Metri-Pack 150 Series (MD GRY)
Pin
Wire Color
Circuit No.
Function
WHT
883
Wheel Speed Sensor Return - Right Rear
BLK
882
Wheel Speed Sensor Signal - Right Rear
Traction Control Disable Switch
Document ID: 393866
Page 6 of 6
12064752
6-Way F Metric Pack 280 Series (BLK)
Pin
Wire Color
Circuit No.
Function
--
--
BLK
1250
Ground
BLK/ WHT
251
Ground
BRN/ WHT
1571
GRY
Instrument Panel Lamp Feed
--
--
Not Used
Not Used
Traction Control System Switch Signal
Document ID: 403395
Page 1 of 1
Repair Instructions | Document ID: 403395
Antilock Brake System Automated Bleed Procedure

The following procedure provides a complete Delco Bosch 5 brake system bleed. The procedure
cycles the system valves and runs the pump in order to purge air from the secondary circuits. The
secondary circuits are normally closed Off during non-ABS/TCS mode operation and bleeding. Use
this procedure when it is suspected that air has been ingested into the secondary circuits, or after
BPMV replacement.
Bleed Instructions
1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove all four tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.
3. Inspect the brake system for leaks and visual damage.
4. Inspect the battery state of charge. Refer to Battery Check in Engine Electrical.
5. Connect the Scan Tool to the DLC.
6. Turn the ignition to RUN. Do not start the engine.
7. Establish communications with the scan tool.
8. Select the ABS/TCS system features.
9. Select Special Functions.
10. Select Auto Bleed Procedure.
11. Bleed the base brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
12. Follow the scan tool driven instructions until the proper brake pedal height is achieved.
13. If any malfunctions are detected, the bleed procedure will be aborted:
If DTCs are present, the scan tool will display DTCs Present or will list the DTCs,
depending on when the DTCs were set.
DTCs can be cleared in the Trouble Codes mode. Refer to the appropriate DTC in order to
clear the DTC.
If the test is aborted but no DTCs are listed, refer to Diagnostic System Check - ABS .
Correct all system malfunctions before attempting the bleed procedure again.
If a road test is required for diagnosis, and the brake pedal is spongy, perform a
conventional brake bleed. Refer to Hydraulic Brake System Bleeding . Achieve a firm
pedal before driving the vehicle.
14. When the auto bleed procedure is complete, perform the following steps:
Press the brake pedal. The brake pedal should be high and firm.
If the pedal is not firm, inspect the brake system for conditions that might cause the
condition. Refer to Brake System Testing in Hydraulic Brakes.
If the brake system is OK, and excess pedal travel persists, repeat the bleed procedure.
15. Disconnect the scan tool.
16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
17. Inspect the brake fluid level and fill as necessary. Refer to Master Cylinder Reservoir Filling in
Hydraulic Brakes.
18. Road test the vehicle while making several ABS/TCS actuations in a suitable area. The brake
pedal should remain high and firm throughout the test.
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2/7/2011
Document ID: 394051
Page 1 of 4
Electronic Brake Control Module Replacement

Removal Procedure
Caution: Do not pry EBCM/EBTCM. Be careful not to damage seal (if reusing module). If seal is
damaged during removal, repair damaged area using GM P/N 123456739 silicone sealer or replace
EBCM/EBTCM.
Important: You may not repair the EBCM/EBTCM. If the assembly is faulty, replace the
EBCM/EBTCM as an assembly.
1. Turn the ignition switch to the OFF position.
2. Remove the air cleaner assembly and the PCM cover. Refer to Air Cleaner Assembly
Replacement in Engine Controls - 3.8L.
3. Disconnect the EBCM/EBTCM harness connector.
4. Remove the front EBCM/EBTCM bracket from the vehicle (5).

5. Remove the EBCM/EBTCM center bracket mounting bolt (4).
Document ID: 394051
Page 2 of 4
6. Remove the 4 EBCM/EBTCM to the BPMV bolts (1).

Important: Do not twist the assembly.
7. Remove the EBCM/EBTCM by pulling rearward until the internal connector disengages.
Installation Procedure
Notice: Be sure to reconnect all harness retaining clips that may have been disconnected during
the removal procedure in their original positions. Then perform a visual inspections of the entire
harness checking to make sure all retaining clips are properly connected.
Important: When replacing the EBCM/EBTCM, you must recalibrate the Magnasteer. Refer to
Variable Effort Steering Programming in Variable Effort Steering.
Document ID: 394051
Page 3 of 4
1. Clean the EBCM/EBTCM seal and the BPMV gasket surface using alcohol.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the
correct part number for that application. Fasteners requiring replacement or fasteners
requiring the use of thread locking compound or sealant are identified in the service
procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
2. Install the EBCM/EBTCM to the BPMV.
Tighten
Tighten the 4 EBCM/EBTCM to BPMV bolts (1) to 6 Nm (53 lb in).
Document ID: 394051
Page 4 of 4
3. Install the front EBCM/EBTCM bracket (5).

Tighten
Tighten the EBCM/EBTCM center bracket mounting bolt (4) to 14 Nm (10 lb ft).
4. Connect the EBCM/EBTCM harness connector.
5. Install the air cleaner assembly and the PCM cover. Refer to Air Cleaner Assembly
6. Turn the ignition switch to the RUN position. Ensure that the engine is off.
7. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .
Document ID: 394054
Page 1 of 8
Brake Pressure Modulator Valve Replacement

Removal Procedure
Caution: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired;
the complete unit must be replaced. With the exception of the EBCM/EBTCM, no screws may be
loosened. If screws are loosened, it will not be possible to get the brake circuits leak-tight and
personal injury may result.
2. Remove the air cleaner assembly and the PCM cover. Refer to Air Cleaner Assembly
3. Disconnect the following connectors:
The EBCM/EBTCM harness connector
The BPMV motor ground cable connector
Important: Note the locations of the brake pipes in order to aid in installation.
4. Remove the front master cylinder brake pipe fittings from the BPMV.
2/7/2011
Document ID: 394054
Page 2 of 8
5. Remove the top master cylinder brake pipe fittings from the BPMV.
6. Remove the wheel brake pipe fittings from the BPMV.

Notice: When removing the brake pressure modulator valve, protect the vehicle exterior
from possible brake fluid spillage. Brake fluid can cause damage to painted surfaces.
Notice: Excessive bending of brake pipes during BPMV removal or installation may cause
permanent damage that will require replacement.
7. Clean any brake fluid spillage from the BPMV.
2/7/2011
Document ID: 394054
Page 3 of 8
8. Remove the front EBCM/EBTCM bracket mounting bolt (4).

9. Remove the front EBCM/EBTCM bracket from the vehicle (5).
10. Remove the upper BPMV bracket from the frame rail (2).
11. Remove the 2 upper bracket to BPMV bolts (1).
12. Remove the EBCM/BPMV as an assembly.
2/7/2011
Document ID: 394054
Page 4 of 8
13. Remove the 4 EBCM/EBTCM to BPMV bolts (1).

Caution: Do not pry EBCM/EBTCM. Be careful not to damage seal (if reusing module). If seal
is damaged during removal, repair damaged area using GM P/N 123456739 silicone sealer or
replace EBCM/EBTCM.
14. Pull rearward in order to separate the EBCM/EBTCM from the BPMV.
1. Clean the EBCM/EBTCM seal and the BPMV gasket surface using alcohol.
2/7/2011
Document ID: 394054
Page 5 of 8
2. Install the EBCM/EBTCM to the BPMV.
Tighten
Tighten the 4 EBCM/EBTCM to BPMV bolts (1) to 4.5 Nm (40 lb in).
Important: If a new BPMV is being installed, remove the shipping plugs from the valve
openings.
3. Install the upper BPMV bracket to the BPMV (2).
4. Install the EBCM/EBTCM and BPMV into the vehicle.
5. Install the 2 BPMV frame rail bolts.
Tighten
Tighten the bolts to 12 Nm (106 lb in).
2/7/2011
Document ID: 394054
Page 6 of 8
6. Install the front EBCM/EBTCM bracket (5).

7. Install the EBCM/EBTCM to BPMV center bolt (4).
Tighten
Tighten the bolt to 14 Nm (10 lb ft).
Caution: Make sure brake pipes are correctly connected to BPMV. If brake pipes are
switched by mistake Inlet vs. Outlet, wheel lockup will occur and personal injury may result.
Important: Use the locations noted during removal.
2/7/2011
Document ID: 394054
Page 7 of 8
8. Install the wheel brake pipe fittings to the BPMV.

Tighten
Tighten the brake pipe fitting at the BPMV to 16 Nm (12 lb ft).

9. Install the top master cylinder brake pipe fittings to the BPMV.
Tighten
2/7/2011
Document ID: 394054
Page 8 of 8

10. Install the front master cylinder brake pipe fittings to the BPMV.
Tighten
11. Connect the following connectors:
The EBCM/EBTCM harness connector
12.
13.
14.
15.
The BPMV motor ground cable connector

Install the air cleaner assembly and the PCM cover. Refer to Air Cleaner Assembly
Fill and bleed the hydraulic brake system. Refer to Master Cylinder Reservoir Filling and
Hydraulic Brake System Bleeding in Hydraulic Brakes.
Turn the ignition switch to the RUN position. Ensure that the engine is off.
Perform the auto bleed procedure. Refer to Antilock Brake System Automated Bleed
Procedure .
Notice: Be sure to reconnect all harness retaining clips that may have been disconnected
during the removal procedure in their original positions. Then perform a visual inspections of
the entire harness checking to make sure all retaining clips are properly connected.
16. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS .
2/7/2011
Document ID: 394167
Page 1 of 3
Rear Wheel Speed Sensor Replacement

Removal Procedure
1.
2.
3.
4.
Disconnect the wheel speed sensor connector (2).

Remove the lower strut attaching fasteners (4).
Clean all dirt and debris from sensor housing/sensor interface area.
Remove the mounting fasteners (3).
Important:
Do not allow debris to enter the bearing when the sensor is removed.
Do not add lubricant to the bearing through the sensor housing opening. The bearing is
lubricated for the life of the vehicle.
Do not clean grease from tooted sensor ring. Grease does not affect the sensor
operation.
5. Remove the sensor.

2/7/2011
Document ID: 394167
Page 2 of 3
1. Lubricate new sensor O-ring.

2. Install the sensor to the housing.
3. Install the mounting fasteners (3) in a spiral pattern.
Tighten
Tighten the mounting fasteners to 2.8 Nm (25 lb in).
4. Install the lower strut attaching fasteners (4).
Tighten
Tighten the lower strut attaching fasteners to 190 Nm (140 lb ft).
2/7/2011
Document ID: 394167
Page 3 of 3
5. Connect the wheel speed sensor connector (2).
2/7/2011
Document ID: 394169
Page 1 of 2
Lamp Driver Module Replacement

Removal Procedure
Important: The internal circuit board is replaceable. The terminals and housing are part of the
wiring harness.
1. Remove the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel, Gauges and Console.
2. Unsnap the brake lamp driver module from the MALL bracket.
3. Open the brake lamp driver module endcap (1) and remove the circuit board by pulling
straight out.
2/7/2011
Document ID: 394169
Page 2 of 2
1. Carefully install the circuit board into the brake lamp driver module case and close the
endcap (1).
2. Snap the brake lamp driver module into the MALL bracket clip.
3. Install the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel, Gauges and Console.
2/7/2011
Document ID: 528753
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Suspension |

Automatic Level Control | Specifications | Document ID: 528753

Specification
Application
Metric
English
4 Nm
36 lb in
10 Nm
88 lb in
Air Compressor Head to Air Compressor Bolts
6 Nm
53 lb in
Air Compressor Relay Screw
3 Nm
27 lb in
Brackets to Air Compressor Screws
7 Nm
62 lb in
Harness Tie to Air Compressor Head Bolt
3 Nm
26 lb in
Height Sensor to Bracket Nuts
2.5 Nm
22 lb in
Height Sensor to Vehicle Bolts
5 Nm
44 lb in
Upper and Lower Height Sensor Link Nuts
7 Nm
62 lb in
Air Compressor to Bracket Bolts

Air Compressor Bracket to Vehicle Nuts
tomsn048@gmail.com
2/7/2011
Document ID: 395184
Page 1 of 1

Automatic Level Control | Schematic and Routing Diagrams | Document ID: 395184
Cell 42: Buick/Oldsmobile
tomsn048@gmail.com
2/7/2011
Document ID: 395185
Page 1 of 1

Automatic Level Control | Schematic and Routing Diagrams | Document ID: 395185
Cell 42: Pontiac
tomsn048@gmail.com
2/7/2011
Document ID: 232223
Page 1 of 1

Automatic Level Control | Component Locator | Document ID: 232223
Below RH Rear of Vehicle
(1) RH Rear Rail

(2) Automatic Level Control Sensor
(3) Automatic Level Control Compressor
tomsn048@gmail.com
2/7/2011
Document ID: 411208
Page 1 of 1

Rear Compartment, Right Side (Pontiac)
(1) Automatic Level Control Relay

(2) Inflator Air Solenoid Valve
(3) P403
tomsn048@gmail.com
2/7/2011
Document ID: 395190
Page 1 of 3

Automatic Level Control Connector End Views

Automatic Level Control Compressor
12129565
4-Way F Metri-Pack 280 Series, Sealed (GRY)
Pin
Wire Color
Circuit No.
Function
BLK
1250
WHT
320
ALC Exhaust Solenoid Output
DK GRN
322
ALC Compressor Motor Feed
RED
1042
Ground
Fused Output - Battery
Automatic Level Control Relay (Pontiac)

Pin
Wire Color
02965977
8-Way F 56 Series (BLK)
Circuit No.
Function
tomsn048@gmail.com
2/7/2011
Document ID: 395190
Page 2 of 3
PPL
1267
ALC Reset Signal
LT BLU
1248
ALC Height Sensor Signal
DK BLU
1249
ALC Inflator Solenoid Valve Feed
RED
1042
YEL
321
ALC Relay Output - Coil
WHT
837
ALC - Inflator Relay Output - Coil
BLK
1250
Not Used
Ground
Automatic Level Control Sensor
12052848
Pin
Wire Color
Circuit No.
BLK
1250
YEL
321
ALC Relay Output - Coil
RED
1042
BRN
641
Fused Output - IGN3
WHT
320
ALC Exhaust Solenoid Output
Function
Ground
Not Used
Inflator Air Solenoid Valve (Pontiac)
tomsn048@gmail.com
2/7/2011
Document ID: 395190
Page 3 of 3
02984951
Pin
Wire Color
Circuit No.
DK BLU
1249
ALC Inflator Solenoid Valve Feed
BLK
1250
Ground
Function
Inflator Switch (Pontiac)
12015683
3-Way F Pin Grip Connector (BLK)
Pin
Wire Color
Circuit No.
Function
WHT
837
BLK
1250
Ground
PPL
1267
ALC Reset Signal
ALC Inflator Relay Output - Coil
tomsn048@gmail.com
2/7/2011
Document ID: 529249
Page 1 of 2

Automatic Level Control | Repair Instructions | Document ID: 529249
Automatic Level Control Air Dryer Replacement

Removal Procedure
1. Remove the air compressor assembly with the bracket from the vehicle. Refer to Air
Compressor Replacement .
2. Remove the air compressor bracket from the air compressor.
3. Rotate the spring clip 90 degrees out of the slot.

4. Remove the air dryer from the air compressor assembly.
5. Remove the seal from the air compressor, if the seal did not come off with the air dryer.
Important:
Lubricate the seal with silicone lubricant.
Spring clip must not be in slots of the air compressor.
1. Install a new seal onto the air dryer.
tomsn048@gmail.com
2/7/2011
Document ID: 529249
Page 2 of 2
2. Install the air dryer with the seal in the air compressor.
3. Rotate the spring clip 90 degrees to lock the air dryer in place.
4. Install the air compressor bracket on the air compressor.
Important: Before driving the vehicle, turn the ignition on and wait approximately 45
seconds. This will permit the ELC system to execute the ARC, ensuring that the air adjustable
struts are filled with residual pressure.
5. Install the air compressor assembly with the bracket onto the vehicle. Refer to Air
Compressor Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 528756
Page 1 of 2

Automatic Level Control Air Compressor Air Filter

Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Important: Before disconnecting the air hose from the intake air filter or the air compressor,
clean the components and the surrounding area to prevent dirt and other foreign material
from entering the air compressor.
2. Disconnect the intake air filter from the body rail and the air hose.
tomsn048@gmail.com
2/7/2011
Document ID: 528756
Page 2 of 2
1. Connect the intake air filter to the air hose and the body rail.
2. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
tomsn048@gmail.com
2/7/2011
Document ID: 529250
Page 1 of 3

Automatic Level Control Sensor and Bracket

Replacement
Removal Procedure
2. Disconnect the link from the height sensor actuating arm and the suspension control arm.
3. Remove the height sensor connector from the vehicle harness connector.
4. Remove the height sensor harness clip and the connector from the vehicle.
tomsn048@gmail.com
2/7/2011
Document ID: 529250
Page 2 of 3
5. Remove the two bolts and the height sensor with the bracket from the vehicle.
6. Remove the four nuts and the bracket from the height sensor.
1. Install the bracket on the height sensor with four nuts.
Tighten
Tighten four nuts to 3 Nm (26 lb in).
2. Install the height sensor with the bracket on the vehicle with two bolts.
Tighten
Tighten two bolts to 5 Nm (44 lb in).
3. Connect the height sensor harness clip and the connector to the vehicle.
4. Connect the height sensor connector to the vehicle harness connector.
tomsn048@gmail.com
2/7/2011
Document ID: 529250
Page 3 of 3
5. Connect the link to the height sensor actuating arm and the suspension control arm.
7. Adjust the height sensor. Refer to Automatic Level Control Sensor Adjustment .
tomsn048@gmail.com
2/7/2011
Document ID: 529252
Page 1 of 2

Automatic Level Control Sensor Adjustment

The link must be attached to the height sensor arm and the suspension control arm during the
adjustment.
1. Park the vehicle on a level floor.
2. Check the following:
Check the tire inflation pressures and adjust if necessary.
Check the fuel level in the tank; the tank should be full or adjust the rear suspension
loading to simulate a full fuel load: 3.75 liters (1 gal) weighs about 3.2 kg (7 lb).
No other load is in the vehicle.
Place the front seat in rear position.
Turn the ignition to ON to activate the system.
Bounce the rear of the vehicle three times to normalize the suspension.
Measure the trim height at the rear underbody points on both sides of the vehicle. Refer to
Trim Height in Suspension General Diagnostics.
7. If the trim heights vary from side to side more than 19 mm (0.75 in), and BOTH trim heights
are lower than 236 mm (9.281 in), then there is a problem with the rear springs or
suspension.
3.
4.
5.
6.
Important: DO NOT continue this procedure until the above suspension problem is
corrected.
8. Loosen the lock bolt (5) that clamps the metal actuating arm (4) to the plastic actuating arm.
To increase the trim height, move the plastic arm up in relation to the metal arm; to
decrease the trim height, move the plastic arm down in relation to the metal arm.
9. Tighten the lock bolt.
10. Bounce the rear of the vehicle three times to normalize the rear suspension.
11. Measure the trim height at the rear underbody points on both sides of the vehicle. Refer to
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Document ID: 529252
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Trim Height in Suspension General Diagnostics.
Optional Sensor Adjustment Method

Special Tool J 34825 may be used for sensor adjustment. Instructions are provided with the tool.
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Document ID: 529254
Page 1 of 3

Automatic Level Control Air Compressor Head

Replacement
Disassembly Procedure
1. Remove the air compressor from the vehicle. Refer to Air Compressor Replacement .
2.
3.
4.
5.
Remove the air compressor harness from the air compressor bracket.
Remove the air dryer. Refer to Automatic Level Control Air Dryer Replacement .
Cut the harness tie.
Remove the bolt and the harness tie.
Important: Note the wire colors and the terminal numbers to ensure correct assembly.
6. Remove the two harness ties and the wrap from the wires.
7. Remove two wire terminals from the air compressor connector.
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8. Remove the air hose from the air compressor head.

9. Remove three head bolts and the air compressor head from the air compressor assembly.
10. Remove the gasket from the air compressor head or the air compressor assembly.
Assembly Procedure
1. Install the new gasket on the air compressor assembly.

2. Install the air compressor head on the air compressor assembly with three bolts.
Tighten
Tighten three bolts to 6 Nm (53 lb in).
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3.
4.
5.
6.
Page 3 of 3
Connect the air hose to the air compressor head.

Install the two wire terminals in the air compressor connector.
Install the wrap around four wires and secure with two harness ties.
Install four wires in the harness tie and install the harness tie on the air compressor head
with the bolt.
Tighten
Tighten the bolt to 3 Nm (26 lb in).
7. Install the air dryer. Refer to Automatic Level Control Air Dryer Replacement .
8. Connect the air compressor harness on the air compressor bracket.

9. Install the air compressor on the vehicle. Refer to Air Compressor Replacement .
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Document ID: 529257
Page 1 of 4

Air Tube Replacement
At the rear struts and at the pressure limiter valve, the air tube connectors are held on with spring
clips which snap into the grooves of the struts air fittings or pressure limiter valve. Air tube
connectors are sealed using two O-rings.
Important: Before disconnecting any air tube, clean the connector and the surrounding area to
prevent dirt and other foreign material from entering the ALC system.
To disconnect an air tube from a strut or from the pressure limiter valve, rotate the spring clip 90
degrees out of the slots, and pull the connector off.
Important: Ensure that the air tube is routed correctly and all fasteners are used.
To connect an air tube to a strut or to the pressure limiter valve, use the following instructions:
1. Lubricate the two O-rings using silicone lubricant.
2. Rotate the spring clip 90 degrees into the slots.
3. Push the air tube connector on the strut fitting or pressure limiter valve until the spring clip
snaps into the groove.
Removal Procedure
Important: Steps 2 through 4 apply to the air tube that is routed from the air compressor to
the crossover air tube. Step 5 through 8 apply to the crossover air tube (routed between the
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struts).
2. Disconnect the air tube from the pressure limiter valve.
3. Remove the air tube from the height sensor harness clips.
4. Disconnect the air tube from the crossover air tube tee (1) or the inflator valve air tube (2)
(vehicles with optional inflator valve only).
5. Remove both rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
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6.
7.
8.
9.
Page 3 of 4
Disconnect the crossover air tube from the right strut and two clips.
Disconnect the crossover air tube from the left strut and two clips.
Disconnect the air tube (coming from the air compressor) from the crossover air tube tee.
Remove the crossover air tube tee from the vehicle.
Important: Steps 1 through 5 and 8 apply to the crossover air tube (routed between the
struts). Steps 5 through 8 apply to the air tube that is routed from the air compressor to the
crossover air tube.
1. Install the crossover air tube tee on the vehicle.
2. Connect the air tube to the right rear strut and install the air tube in two clips.
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3. Connect the air tube to the left rear strut and install the air tube in two clips.
4. Install both rear wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
5. Connect the air tube (from the air compressor) to the crossover air tube tee (1) or the
inflator valve air tube (2) (vehicles with optional inflator valve only).
6. Install the air tube in the height sensor harness clips.

7. Connect the air tube to the pressure limiter valve.
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Air Compressor Replacement

Removal Procedure
1. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General
Information.
Important: Before disconnecting any air hose or air tube, clean the components and the
surrounding area to prevent dirt and other foreign material from entering the ELC system.
2. Disconnect the air tube from the pressure limiter valve.
3. Remove the air tube from the air compressor bracket.
4. Remove the intake air filter from the vehicle.
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5. Remove the height sensor harness from the air compressor bracket.
6. Disconnect the vehicle harness connector from the air compressor connector.
7. Remove the four nuts and the air compressor assembly from the vehicle.
8. Disconnect the pressure limiter valve air tube from the air dryer.
9. Remove the pressure limiter valve from the clip.
10. Remove the air compressor harness from the air compressor bracket.
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11. Remove three bolts and the air compressor assembly from the bracket.
12. Remove the air dryer from the air compressor. Refer to Automatic Level Control Air Dryer
Replacement .
13. Remove the air hose from the air compressor at two places.
14. Remove the two screws and the two brackets from the air compressor.
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1. Install the two brackets on the air compressor with two screws.
Tighten
Tighten two screws to 7 Nm (62 lb in).
2. Connect the air hose to the air compressor at two places.
3. Install the air dryer on the air compressor. Refer to Automatic Level Control Air Dryer
Replacement .
4. Install the air compressor assembly onto the bracket with three bolts.
Tighten
Tighten three bolts to 4 Nm (36 lb in).
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5. Connect the pressure limiter valve air tube to the air dryer.
6. Install the pressure limiter valve in the clip.
7. Install the air compressor harness onto the air compressor bracket.
8. Install the air compressor assembly on the vehicle with four nuts.
Tighten
Tight four nuts to 10 Nm (88 lb in).
9. Connect the vehicle harness connector to the air compressor connector.
10. Install the height sensor harness on the air compressor bracket.
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11. Install the intake air filter on the vehicle.

12. Connect the air tube to the pressure limiter valve.
13. Install the air tube on the air compressor bracket.
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Document ID: 298875
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories |
Body Front End | Specifications | Document ID: 298875

Specification
Application
Metric
English
Air Inlet Grille Panel Screws
1.9 Nm
17 lb in
Center Brace to Radiator Support Bolts
13 Nm
115 lb in
Fender Sound Insulator Bolts
1.7 Nm
17 lb in
Fender to Body Bolts
9.5 Nm
84 lb in
Front End Panel to Body Bolts
5 Nm
44 lb in
Grille Bolts - Eighty Eight/LSS
4 Nm
35 lb in
Grille Bolts - Regency
1.9 Nm
17 lb in
Grille to Hood Bolts - Pontiac
1.9 Nm
17 lb in
Grille to Hood Nuts - Buick
1.9 Nm
17 lb in
Hood Hinges to Upper Rail Bolts
29 Nm
21 lb ft
Hood Latch Release Handle Bolts
7 Nm
62 lb in
Hood Panel to Hinge Bolts
29 Nm
21 lb ft
Lower Air Deflector Bolts
7.5 Nm
66 lb in
Primary Latch Bolts
9.5 Nm
84 lb in
Secondary Latch to Hood Bolts
9.5 Nm
84 lb in
Side Brace to Center Brace on Radiator Support Bolts
9.5 Nm
84 lb in
Wheel Opening Molding Screws - Buick
1.9 Nm
17 lb in
Wheel Opening Molding Screws - Eighty Eight/LSS
2.1 Nm
18 lb in
Wheelhouse Assembly Bolts
1.9 Nm
17 lb in
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Body Front End | Repair Instructions | Document ID: 298876
Hood Ajar Indicator Switch Replacement

Removal Procedure
1. Gently pry the hood ajar switch (1) from the radiator support (2).
2. Disconnect the electrical connector (3) from the switch.
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1. Connect the electrical connector (3) to the switch.

2. Press the hood ajar switch (1) to the radiator support (2).
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Hood Adjustment
1.
2.
3.
4.
Open the hood (1).

Remove the hood primary latch. Refer to Hood Primary and Secondary Latch Replacement .
Remove the hood pop up spring. Refer to Hood Pop-Up Spring Replacement .
With the hood (1) in the closed position, verify the adjustment of the rear portion of the hood
panel. Ensure that the following conditions exist:
Ensure that the hood panel is flush (up/down) with the fenders.
Perform up/down adjustments at the hood to hinge bolts (2), as needed.
Ensure that there are even gaps (side-to-side) between the hood panel and the fenders.
Perform side-to-side adjustments at the hinge to body bolts as needed.
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5. With the hood (1) in the closed position, verify the flushness (up/down) of the front portion
of the hood panel to the fenders.
Perform up/down adjustments at the front hood bumpers (2) as needed.
6. Install the hood pop up spring. Refer to Hood Pop-Up Spring Replacement .
7. Install the hood primary latch. Refer to Hood Primary and Secondary Latch Replacement .
8. Adjust the hood primary latch. Refer to Hood Latch Adjustment .
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Document ID: 298883
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Hood Bumper Replacement

Removal Procedure
1. Remove the front bumpers (2) using the following procedure:

1.1. Peel the bumper (7) from the bumper adjuster (6).
1.2. Use a flat bladed tool in order to pry the bumper adjuster (6) from the radiator
support (5).
2. Peel the side bumper (4) from the fender in order to remove the side bumper (4).
3. Twist the rear bumper in order to remove from the hood (1).
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4. Twist the front overslam bumpers (2) in order to remove from the hood (1).
Important: Do not use the front overslam bumpers (2) for adjustment.
1. Twist the front overslam bumpers (2) in order to install into the hood.
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2. Use the following procedures in order to install the rear bumper (2) :
2.1. Twist the rear bumper (2).
2.2. Ensure that the rear bumper is 13 mm ( in) from the hood (1).
3. Press the side bumpers (4) to the fender in order to engage.
4. Use the following procedure in order to install the front bumpers (6):
4.1. Press the front bumper (6) into the radiator support (5).
4.2. Connect the front bumper (7) to the front bumper adjuster (6).
4.3. Adjust the hood panel. Refer to Hood Adjustment .
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Hood Replacement
Removal Procedure
Important: Install protective coverings over the fenders in order to prevent damage to the
paint and the moldings when removing or installing the hood (1).
1. Raise the hood (1).
2. Disconnect the underhood lamp wire (if applicable).
3. Mark the position of the hinge (3) on the hood (1) in order to aid in the alignment when the
hood is reinstalled.
4. Complete the following steps:
4.1. Support the hood (1).
4.2. Loosen the ball socket retainers.
4.3. Pry off the assist rods.
5. Remove the following components that retain the hood (1) to the hinges:
The bolts (2)
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The nuts (4)

6. Remove the hood (1).
1. Position the hood (1) in the location marked during the removal.
2. Install the following components in order to retain the hood (1) to the hinges:
The bolts (2)
The nuts (4)
Tighten
Tighten the bolts and the nuts to 29 Nm (21 lb ft).
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3. Install the open-assist rods.

4. Reconnect the underhood lamp (if applicable).
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Page 1 of 2
Hood Hinge Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the hood panel. Refer to Hood Replacement .

Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
Loosen the fender. Refer to Front Fender Replacement .
Remove the bolts (2) that retain the hood hinge (1) to the upper rail.
Remove the hinge (1) .
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1. Install the hood hinge (1) .

2. Install the bolts (2) in order to retain the hinge (1) to the upper rail.
Tighten
Tighten the bolts to 29 Nm (21 lb ft).
3.
4.
5.
6.
Install the fender. Refer to Front Fender Replacement .

Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
Install the hood.
Inspect the hood for proper alignment.
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Document ID: 298887
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Hood Latch Adjustment
1. Loosen the bolts (2).

2. Ensure that the top edge of the hood primary latch (1) is 61 mm (2.4 in) from the top of the
radiator support (4). This is the starting point for the up/down latch adjustment.
3. Snug the bolts (2) in order to hold the latch in position.
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4. Lower the hood (1). Ensure that the striker does not engage with the latch.
5. Verify the side-to-side adjustment of the latch to the striker.
6. Raise the hood (1).
7. Tighten the primary latch bolts.
Tighten
Tighten the bolts to 9.5 Nm (84 lb in).
8. Perform a hood drop test in order to determine the need for up/down latch adjustment. The
hood drop test determines the amount of drop force required in order to fully engage the
striker with the latch.
9. Complete the following steps in order to perform the hood drop test:
9.1. Place a ruler (2) capable of measuring millimeters, between the hood (1) and the
fender (3).
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9.2. Raise the hood (1).

9.3. Ensure that the front upper edge of the hood is 80 mm (3 1/8 in) above the top
surface of the fender (3). This determines if the latch is set to high.
9.4. Drop the hood (1). The striker should not engage with the latch.
10. Increase the measurement to 95 mm in order to repeat the test. If the striker engages with
the latch below 110 mm (4 1/4 in) test height, the latch is too high.
11. Repeat the test at the following heights. Ensure that the striker engages in this range:
110 mm (4 1/4 in)
160 mm (6 3/8 in)
12. If the striker does not engage at 160 mm (6 3/8 in) the latch is too low.
13. Adjust the latch as needed.
14. Tighten the bolts.
Tighten
15. Verify that the latch operates properly.
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Hood Primary and Secondary Latch Replacement

Removal Procedure
The hood latch is attached to the radiator support. The bolts are elongated in order to help in
adjustment. Lubricate the hood latch as recommended. Refer to Fluid and Lubricant
Recommendations in General Information.
1.
2.
3.
4.
Remove the upper radiator support (3).

Disconnect the hood release cable from the hood latch (1).
Remove the bolts (2) that retain the hood latch.
Remove the hood latch (1).
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1. Install the hood latch (1).

2. Install the bolts (2) in order to retain the hood latch.
Tighten
3. Connect the hood release cable to the hood latch.
4. Install the upper radiator support (3).
5. Adjust the hood primary latch (1). Refer to Hood Latch Adjustment .
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Document ID: 298889
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Hood Primary Latch Release Cable Replacement

Removal Procedure
1. Open the hood.

2. Disconnect the release cable (1) from the latch assembly (2).
3. Route the cable along the body rail towards the rear of the vehicle.
Important: Tie a string around the cable before removing the cable from the vehicle. This
will ensure the proper routing and ease of installation of the release cable.
4.
5.
6.
7.
Remove the 2 bolts that retain the hood latch release handle .
Remove the grommet through the cowl opening.
Remove the cable through the passenger compartment.
Disconnect the cable from the release handle.
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1. Connect the cable to the release handle .

2. Install the cable through the passenger compartment.
Important: Apply a mild soap in order to ease installation.
3. Install the grommet through the cowl opening.
4. Install the 2 bolts in order to retain the hood latch release handle .
Tighten
5. Route the cable along the body rail toward the front of the vehicle.
6. Connect the release cable (1) to the latch assembly (2).
7. Close the hood.
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Document ID: 298890
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Hood Pop-Up Spring Replacement

Removal Procedure
1. Remove the pop-up spring cover.

2. Remove the bolt (1) retaining the pop-up spring (2).
3. Remove the pop-up spring (2).
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1. Install the pop-up spring (2).

2. Install the bolt (1) in order to retain the pop-up spring (2).
Tighten
Tighten the bolt to 9.5 Nm (84 lb in).
3. Install the pop-up spring cover.
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Document ID: 298891
Page 1 of 2
Hood Insulator Replacement

Removal Procedure
1. Remove the push-in retainers (3) from the hood (1).

2. Remove the hood insulator (2).
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1. Install the hood insulator (2).

2. Install the push-in retainers (3) to the hood (1).
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Document ID: 298892
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Hood Open Assist Rod Replacement

Removal Procedure
Caution: When a hood hold open device is being removed or installed, provide alternate
support to avoid the possibility of damage to the vehicle or personal injury.
1.
2.
3.
4.
Open the hood (1).

Prop up the hood (1).
Loosen the ball socket retainers.
Pry off the assist rod (2).
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1.
2.
3.
4.
Page 2 of 2
Install the assist rod (2).

Tighten the ball socket retainers.
Remove the hood prop.
Lower the hood (1).
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Headlamp Bracket Replacement (Buick/Pontiac)

Removal Procedure
1. Remove the headlamp. Refer to Headlamp Replacement or Headlamp Replacement in
Lighting Systems.
2. Remove the bolts (1) that retain the headlamp mounting bracket (3) to the radiator
support (2).
3. Remove the headlamp mounting bracket (3).
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1. Install the headlamp mounting bracket (3).

2. Install the bolts (1) in order to retain the headlamp mounting bracket (3).
Tighten
3. Install the headlamp. Refer to Headlamp Replacement or Headlamp Replacement in Lighting
Systems.
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Document ID: 298897
Page 1 of 2
Front Air Deflector Replacement

Removal Procedure
1. Remove the bolts (2) retaining the air deflector (1) to the frame.
2. Remove the air deflector (1).
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1. Install the air deflector (1).

2. Install the bolts (2).
Tighten
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Document ID: 298902
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Front Fender Replacement (88/LSS)

Removal Procedure
1. Remove the headlamp. Refer to Headlamp Replacement in Lighting Systems.
2. Remove the hood panel. Refer to Hood Replacement .
3. Remove the wheel opening molding, if equipped. Refer to Front Fender Wheel Opening
Molding Replacement in Exterior Trim.
4. Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
5. Remove the rocker panel molding. Refer to Rocker Panel Molding Replacement .
6. Remove the bolts (3) retaining the fender (1) at the rocker panel.
7. From inside the wheel opening, remove the bolts and nuts (4) retaining the rear of the
fender (1).
8. Remove the bolts retaining the fender (1) at the headlamp opening.
9. Remove the bolts (5) retaining the upper edge of the fender (1).
10. Remove the fender (1).
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1. Install the fender (1).

2. Install the bolts (5) in order to retain the upper edge of the fender (1).
Tighten
3. Install the bolts in order to retain the fender at the headlamp opening.
Tighten
4. From inside the wheel opening, install the bolts and nuts (4) in order to retain the rear of the
fender (1).
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Tighten
5. Install the bolts (3) in order to retain the fender (1) at the rocker panel.
Tighten
6. Install the rocker panel molding. Refer to Rocker Panel Molding Replacement .
7. Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
8. Install the wheel opening molding, if equipped. Refer to Front Fender Wheel Opening Molding
Replacement in Exterior Trim.
9. Install the hood panel. Refer to Hood Replacement .
10. Install the headlamp assembly. Refer to Headlamp Replacement in Lighting Systems.
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Document ID: 298903
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Front Fender Replacement (Pontiac)

Removal Procedure
1.
2.
3.
4.
Remove
Remove
Remove
Remove
Trim.
the
the
the
the
headlamp. Refer to Headlamp Replacement in Lighting Systems.

hood panel. Refer to Hood Replacement .
wheelhouse panel. Refer to Wheelhouse Panel Replacement .
rocker panel molding. Refer to Rocker Panel Molding Replacement in Exterior
5.
6.
7.
8.
9.
Remove the bolts (3) retaining the fender (1) at the rocker panel.
From inside the wheel opening, remove the bolts (4) retaining the rear of the fender (1).
Remove the bolts retaining the fender (1) at the headlamp opening.
Remove the bolts (5) retaining the upper edge of the fender (1).
Remove the fender (1).
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1. Install the fender (1) .

2. Install the bolts (5) in order to retain the upper edge of the fender (1) .
Tighten
3. Install the bolts in order to retain the fender (1) at the headlamp opening.
Tighten
4. From inside the wheel opening, install the bolts (4) in order to retain the rear of the
fender (1).
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Tighten
5. Install the bolts (3) in order to retain the fender (1) at the rocker panel.
Tighten
6.
7.
8.
9.
Install
Install
Install
Install
the
the
the
the
rocker panel molding. Refer to Rocker Panel Molding Replacement in Exterior Trim.
wheelhouse panel. Refer to Wheelhouse Panel Replacement .
hood panel. Refer to Hood Replacement .
headlamp assembly. Refer to Headlamp Replacement in Lighting Systems.
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Document ID: 514851
Page 1 of 2
Front Fender Replacement (Buick)

Removal Procedure
1. Remove the headlamp. Refer to Headlamp Replacement in Lighting.

2. Remove the hood panel. Refer to Hood Replacement .
3. Remove the wheel opening molding. Refer to Front Fender Wheel Opening Molding
4. Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
5. Remove the rocker panel molding. Refer to Rocker Panel Molding Replacement in Exterior
Trim.
6. Remove the bolts retaining the fender (1) at the rocker panel.
7. From inside the wheel opening, remove the bolts and the nuts (3) retaining the rear of the
fender (1).
8. Remove the bolts and the nuts retaining the upper edge of the fender.
9. Remove the fender.
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Document ID: 514851
Page 2 of 2
1. Install the fender.

2. Install the bolts and the nuts in order to retain the upper edge of the fender.
3. From inside the wheel opening, install the bolts and the nuts (3) in order to retain the rear of
the fender (1).
4. Install the bolts in order to retain the fender (1) at the rocker panel.
5. Install the rocker panel molding. Refer to Rocker Panel Molding Replacement in Exterior Trim.
6. Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement .
7. Install the hood panel. Refer to Hood Replacement .
8. Install the wheel opening molding. Refer to Front Fender Wheel Opening Molding
9. Install the headlamp. Refer to Headlamp Replacement in Lighting.
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2/7/2011
Document ID: 298905
Page 1 of 2
Front End Panel Replacement

Removal Procedure
1. Remove the upper filler panel. Refer to Filler Panel Replacement - Upper .
2. Remove the headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.
3. Remove the bolts (2) retaining the front end panel (1) through the headlamp openings.
4. Remove the bolts (2) retaining the front end panel (1) to the center support.
5. Remove the front end panel (1).
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Document ID: 298905
Page 2 of 2
1. Install the front end panel (1).

2. Install the bolts (2) in order to retain the front end panel (1) to the center support.
Tighten
3. Install the bolts (2) in order to retain the front end panel (1) through the headlamp openings.
Tighten
4. Install the headlamp assemblies. Refer to Headlamp Replacement in Lighting Systems.
5. Install the upper filler panel. Refer to Filler Panel Replacement - Upper .
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2/7/2011
Document ID: 298907
Page 1 of 2
Cross Vehicle Brace Replacement

Removal Procedure
1. Remove the nuts (3) retaining the cross vehicle brace (1) to the strut towers.
2. Remove the cross vehicle brace (1).
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2/7/2011
Document ID: 298907
Page 2 of 2
1. Install the cross vehicle brace (1).

2. Loosen the through bolts (2).
3. Adjust the cross vehicle brace (1), as needed.
4. Install the nuts (3) in order to retain the cross vehicle brace (1).
Tighten
Tighten the nuts to 24 Nm (18 lb ft).
5. Tighten the through bolts (2), if previously loosened.
Tighten
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2/7/2011
Document ID: 298909
Page 1 of 3
Support Replacement - Sheet Metal

Removal Procedure
1. Remove the lower air deflector. Refer to Front Air Deflector Replacement .
2. Remove the grille (Regency). Refer to Grille Replacement - Regency.
3. Remove the front end panel. Refer to Front End Panel Replacement .
4. Remove the
brace (4).
5. Remove the
6. Remove the
7. Remove the
bolts (5) that retains the side brace (2) at the radiator support (1) to the center
side brace (2).
bolts (3) retaining the center brace (4) to the radiator support (1).
center brace (4).
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Document ID: 298909
Page 2 of 3
1. Install the center brace (4).

2. Install the bolts (5) in order to retain the center brace (4) to the radiator support (1).
Tighten
3. Install the side brace (2).
4. Install the bolts (3) in order to retain the side brace at the radiator support (1) to the center
brace (4).
Tighten
5. Install the front end panel. Refer to Front End Panel Replacement .
6. Install the grille assembly. Refer to Grille Replacement - Regency.
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2/7/2011
Document ID: 298909
Page 3 of 3
7. Install the lower air deflector. Refer to Front Air Deflector Replacement .
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2/7/2011
Document ID: 298910
Page 1 of 2
Filler Panel Replacement - Upper (88/LSS)

Removal Procedure
1. Remove the push-in retainers (2) from the filler panel (1).
2. Remove the upper filler panel (1).
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Document ID: 298910
Page 2 of 2
1. Install the upper filler panel (1).

2. Install the push-in retainers (2) .
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2/7/2011
Document ID: 298917
Page 1 of 2
Air Inlet Grille Panel Replacement

Removal Procedure
Air ventilation is supplied through the following components:
A grille panel
A heater/air conditioning module
The heater/air conditioning module is located in the plenum chamber.
Air passes through the body and exits through the pressure relief valves. The pressure relief valves
are located on the rear body lock pillars. Refer to Pressure Relief Valve Replacement in Body Rear
End.
1. Raise the hood.
2. Remove the wiper arm assemblies. Refer to Windshield Wiper Arm Replacement in
Wipers/Washers.
3.
4.
5.
6.
7.
8.
Remove the rear hood seal.

Remove the push in/screw retainers.
Remove the right hand wiper transmission bolts under the panel.
Lower the right hand wiper transmission drive shaft.
Disconnect the washer hoses.
Remove the air inlet grille panel.
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2/7/2011
Document ID: 298917
Page 2 of 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Install the washer hoses.

Partially install the air inlet grille panel (1).
Install the wiper transmission bolt under the panel.
Install the wiper transmission bolts through the grille panel.
Install the air inlet grille panel.
Install the wiper transmission bolts through the grille panel.
Install the push in/screw retainers.
Install the rear hood seal.
Install the wiper arm assemblies. Refer to Windshield Wiper Arm Replacement in
Wipers/Washers.
10. Lower the hood.
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2/7/2011
Document ID: 298920
Page 1 of 2
Hood Front Seal Replacement

Removal Procedure
1. Remove the push-in retainers (1).

2. Remove the front hood seal (2).
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2/7/2011
Document ID: 298920
Page 2 of 2
1. Install the front hood seal (2).

2. Install the push-in retainers (1).
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2/7/2011
Document ID: 298922
Page 1 of 2
Hood Rear Seal Replacement

Removal Procedure
Remove the rear hood seal (1) from the flange.
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2/7/2011
Document ID: 298922
Page 2 of 2
1. Apply the weather-strip adhesive GM P/N 12345097 or the equivalent to the seal (1).
2. Press the seal (1) to the flange.
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2/7/2011
Document ID: 298925
Page 1 of 2
Hood Rear Outer Seal Replacement

Removal Procedure
Remove the rear hood seal (1) from the flange.
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2/7/2011
Document ID: 298925
Page 2 of 2
1. Apply the weather-strip adhesive GM P/N 12345097 or the equivalent to the seal (1).
2. Press the seal (1) to the flange.
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2/7/2011
Document ID: 298937
Page 1 of 2
Wheelhouse Panel Replacement (Buick)

Removal Procedure
1. Remove the wheel opening molding.
2. Remove the bolts (2).

3. Remove the wheelhouse assembly (1).
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2/7/2011
Document ID: 298937
Page 2 of 2
1. Install the wheelhouse assembly (1).

Tighten
3. Install the wheel opening molding.
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2/7/2011
Document ID: 298945
Page 1 of 2
Wheelhouse Panel Replacement (88/LSS)

Removal Procedure

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Document ID: 298945
Page 2 of 2

Tighten
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2/7/2011
Document ID: 298947
Page 1 of 2
Wheelhouse Panel Replacement (Pontiac)

Removal Procedure

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2/7/2011
Document ID: 298947
Page 2 of 2

Tighten
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2/7/2011
Document ID: 298949
Page 1 of 2
Front Fender Insulator Replacement

Removal Procedure
1. Remove the wheelhouse assembly. Refer to Wheelhouse Panel Replacement .
2. Remove the bolts (2) retaining the sound insulator (1).

3. Remove the fender sound insulator (1).
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2/7/2011
Document ID: 298949
Page 2 of 2
1. Install the fender sound insulator (1).

2. Install the bolts (2) in order to retain the sound insulator (1).
Tighten
3. Install the wheelhouse assembly. Refer to Wheelhouse Panel Replacement .
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2/7/2011
Document ID: 298951
Page 1 of 2
Engine Splash Shield Replacement

Removal Procedure
1. Remove the push-in retainers (2) from the splash shields (1,3).
2. Remove the engine splash shields (1,3).
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2/7/2011
Document ID: 298951
Page 2 of 2
1. Install the engine splash shields (1,3).

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2/7/2011
Document ID: 298955
Page 1 of 1
Body Rear End | Specifications | Document ID: 298955

Specification
Application
Metric
English
Fuel Filler Door Retaining Nuts
9 Nm
80 lb in
Latch Striker to Body Bolts
9 Nm
80 lb in
Lid Latch to Rear Compartment Bolts
10.5 Nm
93 lb in
Jack Storage Container
13.5 Nm
119 lb in
Rear Compartment Lid Hinges to Body Bolts
18 Nm
13 lb ft
Rear Compartment Lid to Hinge Bolts
25 Nm
18 lb ft
Spoiler to Rear Compartment Lid Bolts - Pontiac
7.5 Nm
66 lb in
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2/7/2011
Document ID: 363458
Page 1 of 1
Body Rear End | Schematic and Routing Diagrams | Document ID: 363458
Release Systems Schematics

Cell 134
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2/7/2011
Document ID: 343474
Page 1 of 1
Body Rear End | Component Locator | Document ID: 343474
Rear Compartment Lid (Buick)
(1) LH License Lamp

(2) RH License Lamp
(3) Rear Compartment Lid Release Solenoid
(4) S400
(5) S414
(6) P405
(7) Rear Compartment Lid Latch Switch
(8) C430
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2/7/2011
Document ID: 359832
Page 1 of 3
Body Rear End | Component Locator | Document ID: 359832
Body Rear End Connector End Views

Table 1:
Rear Compartment Lid Release Actuator
Table 2:
Rear Compartment Lid Release Switch
Table 3:
Rear Compartment Lid Tamper Switch
Table 4:
Valet Switch -- Buick
Table 5:
Valet Switch -- Oldsmobile
Table 6:
Valet Switch -- Pontiac
12052832
Pin
Wire Color
Circuit No.
BLK/WHT
56
BLK
1350
Function
Ground
Rear Compartment Lid Release Switch
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2/7/2011
Document ID: 359832
Page 2 of 3
12015197
Connector Part
Information
2 Way F Metri-Pack 280 Series (BLU)
Pin
Wire Color
Circuit
No.
LT BLU
434
BLK
1576
Function
Transmission Mounted Neutral Safety Switch
Signal
Trunk Release Switch Output
08900863
Pin
Wire Color
Circuit No.
LT BLU
263
BLK
1250
Function
Tamper Switch Signal
Ground
Valet Switch -- Buick
12064868
2-Way M Metric Pack 150 Series
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2/7/2011
Document ID: 359832
Page 3 of 3
Pin
Wire Color
Circuit No.
LT BLU
1344
Trunk Release Relay Output
BLK
1576
Function
Valet Switch -- Oldsmobile
12066510
2-Way F Metric Pack 480 Series (BLU)
Pin
Wire Color
Circuit No.
Function
LT BLU
1344
Trunk Release Relay Output Coil
BLK
1576
Valet Switch -- Pontiac
12064749
Pin
Wire Color
Circuit No.
Function
LT BLU
1344
Trunk Release Relay Output Coil
BLK
1576
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2/7/2011
Document ID: 298957
Page 1 of 2
Body Rear End | Repair Instructions | Document ID: 298957
Spare Tire Replacement

Removal Procedure
1. Remove the spare tire cover (1).

2. Remove the spare tire hold-down (2).
3. Remove the spare tire (3).
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2/7/2011
Document ID: 298957
Page 2 of 2
1. Properly position the spacer blocks (4) in the spare tire well.
2. Install the spare tire (3).
3. Install the spare tire hold-down (2).
Tighten
Tighten the spare tire hold-down to 5.5 Nm (49 lb in).
4. Install the spare tire cover (1).
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2/7/2011
Document ID: 298960
Page 1 of 2
Spare Wheel and Hold-Down Replacement

Removal Procedure
1. Remove the spare tire hold-down (2).

2. Remove the spare tire cover (1).
3. Remove the spare tire (3).
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Document ID: 298960
Page 2 of 2
1. Install the spare tire (3).

2. Install the spare tire cover (1).
3. Install the spare tire hold-down (2).
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2/7/2011
Document ID: 298961
Page 1 of 2
Jack and Tool Stowage Replacement

Removal Procedure
1. Open the jack storage container (1).

2. Remove the bolts (2) that retain the container to the body.
3. Remove the jack storage container (1).
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2/7/2011
Document ID: 298961
Page 2 of 2
1. Install the jack storage container (1).

2. Install the bolts (2) in order to retain the container (1) to the body.
Tighten
3. Close the jack storage container (1).
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2/7/2011
Document ID: 298964
Page 1 of 2
Rear Compartment Side Trim Replacement - Left Side

Removal Procedure
1. Remove the push-in retainers (2).

2. Remove the convenience net retainers.
3. Remove the rear compartment side trim (1).
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2/7/2011
Document ID: 298964
Page 2 of 2
1. Install the rear compartment side trim (1).

2. Install the convenience net retainers.
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2/7/2011
Document ID: 298965
Page 1 of 2
Rear Compartment Side Trim Replacement - Right Side

Removal Procedure
1. Remove the push-in retainers.

2. Remove the convenience net retainers.
3. Remove the rear compartment side trim (1).
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2/7/2011
Document ID: 298965
Page 2 of 2
1. Install the rear compartment side trim (1).

2. Install the convenience net retainers.
3. Install the push-in retainers.
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2/7/2011
Document ID: 298968
Page 1 of 2
Convenience Net Replacement - Rear Compartment

Removal Procedure
1. Remove the retainers (2,3).

2. Remove the convenience net (1).
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2/7/2011
Document ID: 298968
Page 2 of 2
1. Install the convenience net (1).

2. Install the retainers (2,3).
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2/7/2011
Document ID: 299860
Page 1 of 2
Rear Floor Trim Plate Replacement

Removal Procedure
1. Fold the trim assembly (1) until the bottom edges meet in the center, as shown in the
illustration.
2. Lift and remove the trim (1) from the rear compartment.
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2/7/2011
Document ID: 299860
Page 2 of 2
1. Install the still-folded trim (1) into the rear compartment.

2. Smooth the trim out in order to fit the rear compartment in the following sequence:
2.1. Contour at the rear end of the panel
2.2. Contour at the quarter panel
2.3. Contour at the front of the panel
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2/7/2011
Document ID: 299227
Page 1 of 2
Body Tail Lamp Filler Panel Replacement (Buick)

Removal Procedure
1. Remove the rear compartment sill plate.
2. Remove the tail lamp. Refer to Tail Lamp Replacement in Lighting Systems.
3. Remove the nuts (2) that retain the filler panel (1).
4. Remove the tail lamp filler panel (1).
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2/7/2011
Document ID: 299227
Page 2 of 2
1. Install the tail lamp filler panel (1).

2. Install the nuts (2) in order to retain the filler panel (1).
Tighten
Tighten the nuts to 6 Nm (53 lb in).
3. Install the tail lamp. Refer to Tail Lamp Replacement in Lighting Systems.
4. Install the rear compartment sill plate.
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2/7/2011
Document ID: 299229
Page 1 of 2
Fuel Tank Filler Door Replacement

Removal Procedure
1. Remove the fuel filler pocket. Refer to Fuel Tank Filler Pipe Housing Replacement .
2. Remove the 2 nuts (2).

3. Remove the fuel filler door (1).
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2/7/2011
Document ID: 299229
Page 2 of 2
1. Install the fuel filler door (1).

2. Install the 2 nuts (2).
Tighten
3. Install the fuel filler pocket. Refer to Fuel Tank Filler Pipe Housing Replacement .
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2/7/2011
Document ID: 299231
Page 1 of 2
Fuel Tank Filler Pipe Housing Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
fuel cap.
screw from the latch, if equipped.
screws retaining the filler pipe to the filler pocket (1).
screws (2) retaining the filler pocket (1) to the body.
filler pocket (1) from the body.
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2/7/2011
Document ID: 299231
1.
2.
3.
4.
5.
Install
Install
Install
Install
Install
the
the
the
the
the
Page 2 of 2
filler pocket (1) to the body.

screws (2) retaining the filler pocket (1) to the body.
screws retaining the filler pipe to the filler pocket (1).
screw to the latch, as needed.
fuel cap.
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2/7/2011
Document ID: 299232
Page 1 of 2
Fuel Tank Filler Door Lock Actuator Replacement

Removal Procedure
1. Remove the fuel filler door. Refer to Fuel Tank Filler Door Replacement .
2. Remove the fuel filler door latch. Refer to Fuel Filler Door Release Replacement.
3. Disconnect the electrical connector (1).

5. Remove the fuel filler door latch actuator (2) by pulling the cable (4) and the grommet (5)
through the hole in the body.
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2/7/2011
Document ID: 299232
Page 2 of 2
1. Install the fuel filler door latch actuator (2) by feeding the cable (4) through the hole in the
body. Ensure that the cable is in the fuel filler pocket area.
Important: Fully seat the grommet.
2.
3.
4.
5.
6.
Press the grommet (5) into the hole in the body.

Connect the electrical connector (1).
Install the bolts (3).
Install the fuel filler door latch. Refer to Fuel Filler Door Release Replacement.
Install the fuel filler door. Refer to Fuel Tank Filler Door Replacement .
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2/7/2011
Document ID: 299866
Page 1 of 4
Rear Compartment Lid Adjustment

Torque Rod Adjustment
Tools Required
J 39384-3 Torque Rod Retaining Pin
J 39384-10 Torque Rod Adjustment Bar
1.
2.
3.
4.
Support the rear compartment lid.

Insert the J 39384-3 (3) into the hinge (1).
Insert the J 39384-10 (4) over the end of the torque rod (2).
Adjust the torque rod to 1 of 3 positions for desired tension. In order to decrease the amount
of effort needed to raise the lid, reposition the end of the torque rod in a notch closer to the
rear of the vehicle.
Fore/Aft Adjustment and Flushness

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Document ID: 299866
Page 2 of 4
Important: Verify that the rubber overslam bumpers are completely installed into the rear
compartment lid. Do NOT use the overslam bumpers for adjustment.
1. With the lid (2) in the closed position, verify the fore/aft adjustment of the rear compartment
lid at the rear corners of the lid. Verify the flushness of the lid to the quarters.
If adjustment is necessary, loosen the bolts (1) that connect the rear compartment lid to the
hinge. Adjust the lid.
2. Tighten the hinge bolts (1).
Tighten
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Document ID: 299866
Page 3 of 4
3. If the rear compartment lid is not flush at the rear, loosen the inner latch striker mounting
nut (2). Close the rear compartment lid.
4. From beneath the rear bumper fascia, mark the vertical location of the outer latch striker
mounting nuts (2).
5. Loosen the outer latch striker mounting nuts.
5.1. The latch striker (1) should move upward.
5.2. If the latch striker does not move, the striker is probably at the top of its adjustment
range. Make an adjustment to the latch assembly.
6. Verify that the rear compartment lid remains flush to the quarter panels. Tighten the outer
latch striker mounting nuts (2).
Tighten
7. Tighten the inner latch striker mounting nut.
Tighten
Tighten the nut to 9 Nm (80 lb in).
Lid to Quarter Gaps

1. With the lid in the closed position, inspect the gaps between the rear compartment lid and
the quarter panel. The gaps should be 3-4 mm (3/32-1/8 in), at the front and at the rear
corners of the lid.
If the proper gaps are present, you may need to adjust the latch striker or the latch.
If the proper gaps are not present, complete the following steps in order to adjust the
rear compartment lid.
1. Remove the rear shelf speaker covers.
2. Loosen the lid hinge to the rear shelf attachments.
3. Position the rear compartment lid in the opening in order to obtain the proper gaps.
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2. Loosen the latch mounting bolts.
2/7/2011
Document ID: 299866
Page 4 of 4
3. With an assistant in the rear compartment, gently close the lid until the latch contacts the
latch striker. While holding the lid down, have the assistant snug the latch mounting bolts.
4. Raise the rear compartment lid.
5. Tighten the latch mounting bolts.
Tighten
6. Tighten the bolts that connect the hinge to the shelf.
Tighten
7. Verify the proper operation of the rear compartment lid.
8. Verify the gaps between the rear compartment lid and the quarter panel.
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2/7/2011
Document ID: 299235
Page 1 of 2
Rear Compartment Lid Replacement

Removal Procedure
The rear compartment lid consists of the following components:
An inner panel
An outer panel
These panels are hemmed around the perimeter and bonded together with structural adhesive. The
rear compartment lid hinges are bolted to the rear shelf panel and to the lid.
1. Place protective coverings along adjacent body panels.
2. Remove the rear compartment lid trim, if equipped. Refer to Rear Compartment Lid Inner
Panel Trim Replacement .
3. Disconnect the electrical connectors from the following rear compartment components:
The lid latch assembly
The lamp
4. Tie a string to the wiring harness. Pull the harness from the rear compartment lid, leaving
the string routed through the rear compartment lid and hanging out.
5. Remove the wiring harness from the rear compartment lid.
6. Remove the bolts (1) that retain the rear compartment lid to the hinges.
7. With the aid of a helper, remove the rear compartment lid (2).
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Document ID: 299235
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1. Install the rear compartment lid (2) to the hinges.

2. Install the bolts in order to retain the rear compartment lid to the hinges.
Tighten
3. Pull the wiring harness through the rear compartment lid.
Connect the electrical connectors.
4. Install the rear compartment lid trim, if equipped. Refer to Rear Compartment Lid Inner
Panel Trim Replacement .
5. Remove the protective coverings.
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2/7/2011
Document ID: 299869
Page 1 of 3
Rear Compartment Lid Hinge Replacement

Removal Procedure
Tools Required
1.
2.
3.
4.
Remove the rear

Remove the rear
Remove the rear
Remove the rear
Interior Trim.
compartment lid. Refer to Rear Compartment Lid Replacement .

seat cushion. Refer to Rear Seat Cushion Replacement .
seatback. Refer to Rear Seat Back Replacement .
shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
5. Remove the noise control sealer on the trim panel that connects the rear seat to the rear
window. This will expose the bolts holding the hinge (1) to the body.
6. Complete the following steps in order to relieve the tension on the torque rods (2):
6.1. Insert the J 39384-3 into the hinge.
6.2. Insert the J 39384-10
over the
endCorporation.
of the torque
rod.reserved.
Motors
All rights
2011 General
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Document ID: 299869
Page 2 of 3
7. Remove the torque rod from the adjusting notches.

8. From inside the vehicle, remove the 2 bolts retaining the hinge to the body.
9. Remove the hinge (1).
1. Install the hinge (1) to the body by installing the 2 bolts through the rear seat to the rear
window panel. Have an assistant hold the hinge to the body.
Tighten
Tighten the hinge bolts to 18 Nm (13 lb ft).
Important: Properly seat the torque rod in the hinge between the rear shelf and the
hinge
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Document ID: 299869
Page 3 of 3
assembly.
2.
3.
4.
5.
6.
Install the torque rods (2).

Install the rear compartment lid.
Adjust the rear compartment lid as needed. Refer to Rear Compartment Lid Adjustment .
Install the noise control material.
Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
7. Install the rear seatback. Refer to Rear Seat Back Replacement .
8. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .
9. Install the rear compartment lid. Refer to Rear Compartment Lid Replacement .
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2/7/2011
Document ID: 299236
Page 1 of 3
Rear Compartment Lid Hinge Torque Rod Replacement

Removal Procedure
Tools Required
1.
2.
3.
4.
5.
Remove the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement
Remove the retainer clip from the torque rod (2) at the hinge (1).
From inside the vehicle, loosen, but do NOT remove, the 2 hinge retaining bolts.
Support the rear compartment lid.
Complete the following steps in order to relieve the tension on the torque rod (2):
5.1. Insert the J 39384-3 in the hinge (1).
5.2. Insert the J 39384-10 over the end of the torque rod (2).
6. Remove the torque rod (2) from the adjusting notches.
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Document ID: 299236
Page 2 of 3
Tools Required
1. Install the torque rod (2) between the hinge (1) and the shelf.
Important: Properly seat the torque rod between the rear shelf and the hinge assembly.
2. Slide the torque rod (2) into the hinge (1). Secure the rod with the retainer.
3. Open and close the rear compartment lid in order to confirm that the torque rod (2) is seated
properly.
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2/7/2011
Document ID: 299236
Page 3 of 3

4. Install the hinge retaining bolts.
Tighten
5. Insert the torque rod into the adjustment notch:
5.1. Insert the J 39384-3 in the hinge.
5.2. Insert the J 39384-10 over the end of the torque rod.
6. Adjust the rear compartment lid to the desired tension. Refer to Rear Compartment Lid
Adjustment .
7. Install the rear shelf trim panel. Refer to Rear Window Shelf Trim Panel Replacement
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2/7/2011
Document ID: 299238
Page 1 of 2
Lock System Replacement - Rear Compartment (Buick)

Removal Procedure
1.
2.
3.
4.
5.
6.
Open the lid (1).

Remove the lock cylinder emblem.
Remove the retainer rivets (5) by drilling the rivets out using a 4 mm (5/32 in) drill bit.
Remove the lock cylinder (3).
Disconnect the theft deterrent connector (2).
Remove the gasket (4).
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Document ID: 299238
Page 2 of 2
1.
2.
3.
4.
Install the gasket (4) on the lock cylinder body (3).

Connect the theft deterrent connector (2).
Install the lock cylinder. Engage the lock cylinder shaft with the latch.
Install the retainer to the rear compartment lid by installing a 4x11 mm (5/32x7/16 in)
rivet (5) through the retainer (6) and the lid.
5. Install the emblem.
6. Close the lid.
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2/7/2011
Document ID: 298761
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories | Bumpers |

Specification
Application
Metric
English
Front Fascia to Fenders Nuts
9.5 Nm
84 lb in
Front/Rear Energy Absorbers to Body Bolts and Nuts
27 Nm
20 lb ft
4 Nm
35 lb in
Impact Bar to Energy Absorbers Nuts
27 Nm
20 lb ft
Lower Air Deflector Bolts
2.8 Nm
25 lb in
Rear Fascia to Quarter Nuts
9.5 Nm
84 lb in
Front/Rear Energy Absorbers to Body Side Rail Bolt
2/7/2011
Document ID: 298774
Page 1 of 2
Front Bumper Fascia Air Deflector Replacement (Buick)

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the screws that retain the lower air deflector (4) to the front bumper fascia (1).
3. Remove the lower air deflector (4).
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Document ID: 298774
Page 2 of 2
1. Install the lower air deflector (4).

2. Install the screws in order to retain the lower air deflector (4) to the front bumper fascia (1).
3. Lower the vehicle.
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Document ID: 298793
Page 1 of 2
Front Bumper Fascia Replacement (Buick)

Removal Procedure
2. Remove the lower air deflector. Refer to Front Bumper Fascia Air Deflector Replacement .
3. Remove the screws (1) that retain the front bumper fascia (2) at each front wheel opening.
4. Remove the screws (1) that retain the front bumper fascia to the bottom surface of the
fender (3).
5. Remove the push-in retainers from the radiator splash shield.
6. Disconnect the electrical connectors.
7. Remove the front bumper fascia (2) from the vehicle.
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Document ID: 298793
Page 2 of 2
1.
2.
3.
4.
Install the front bumper fascia (2) on the vehicle.

Install the push-in retainers on the radiator splash shield.
Install the screws (1) in order to retain the front bumper fascia (2) to the bottom surface of
the fender (3).
5. Install the screws in order to retain the front bumper fascia at each front wheel opening.
6. Install the lower air deflector. Refer to Front Bumper Fascia Air Deflector Replacement .
2/7/2011
Document ID: 298799
Page 1 of 2
Front Bumper Fascia Molding Replacement (Buick)

Removal Procedure
1. Gently peel the molding (2) away from the fascia (1).
2. Clean the attaching surface with a general adhesive remover.
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Document ID: 298799
Page 2 of 2
1. Peel the backing away from the adhesive tape on the new molding (2).
2. Apply the molding to the fascia (1).
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Document ID: 298820
Page 1 of 2
Front Bumper Impact Bar Replacement (Buick)

Removal Procedure
2. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
3. Remove the nuts that retain the front impact bar (3) to the energy absorbers.
4. Remember the number and the location of the shims.
5. Remove the front impact bar (3).
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Document ID: 298820
Page 2 of 2
1. Install the front impact bar (3).

2. Loosely install the nuts in order to retain the impact bar (3).
3. Install the shims at the original locations.
4. Install the nuts that retain the impact bar.
Tighten
5. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
2/7/2011
Document ID: 298823
Page 1 of 2
Front Bumper Fascia Energy Absorber Replacement

Removal Procedure
Caution: Failure to observe the following procedure when handling energy absorbers could
cause personal injury.
Do not apply heat to an energy absorber.
Do not weld in the area of an energy absorber.
Do not attempt to repair a damaged energy absorber. Always replace the damaged
energy absorber with a new part.
If an energy absorber is bound-up as a result of a collision such that it cannot extend,
take precautions to avoid spring-back when bending sheet metal. Provide a positive
restraint, such as a chain or cable to hold the bumper in the position it is in. Wear
approved safety glasses and using a 3mm (1/8 inch) drill bit, drill a small hole in the
piston tube near the bumper bracket to relieve gas pressure. Remove the energy
absorber after gas pressure has been relieved.
If an energy absorber is to be scrapped, relieve the gas pressure prior to disposal of the
part. Make an indentation with a center punch in the small cylinder section of the
energy absorber.
Notice: An energy absorber that has a dislodged blowout plug (due to an above 8 km/h
(5 mph) impact) could have insufficient absorber action in impacts below 8 km/h (5 mph).
Complete diagnosis procedures must be followed after a collision to prevent excessive vehicle
damage in any future low speed impacts.
2. Remove the bumper assembly. Refer to or Front Bumper Replacement .
3. Remove the side rail bolt (4).

4. Remove the followingcomponents:
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Document ID: 298823
Page 2 of 2
The 2 bolts (2)

The 2 nuts (3)
5. Remove the energy absorber (1).
6. For the Pontiac, remove the attached fog lamp bracket (5).
1. Install the energy absorber (1).

2. Install the side rail bolt (4).
Tighten
Tighten the side rail bolt to 4 Nm (35 lb in).
3. Install the following components:
The 2 bolts (2)
The 2 nuts (3)
Tighten
Tighten the 2 bolts and the 2 nuts to 27 Nm (20 lb ft).
4. Install the bumper assembly. Refer to or to Front Bumper Replacement .
2/7/2011
Document ID: 298825
Page 1 of 2
Rear Bumper Fascia Molding Replacement (Buick)

Removal Procedure
1. Gently peel the following components away from the fascia (1):
The molding (2)
The nameplate (3)
2. Clean the attaching surface with a general adhesive remover.
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Document ID: 298825
Page 2 of 2
1. Peel the backing away from the adhesive tape on the new molding (2) and on the
nameplate (3).
2. Apply the following components to the fascia (1):
The molding (2)
The nameplate (3)
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Document ID: 298832
Page 1 of 2
Rear Bumper Replacement (Buick)

Removal Procedure
2. Remove the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate
Replacement .
3. Remove the rear compartment side trim. Refer to Rear Compartment Side Trim Replacement
- Left Side and to Rear Compartment Side Trim Replacement - Right Side .
4.
5.
6.
7.
8.
9.
Remove
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
the
nuts (5) that retain the fascia (3) to the quarter panels.
nuts (1) that retain the fascia to the rear end panel (2).
screws that retain the wheelhouse extensions to the fascia.
clips (4) that retain the fascia to the taillamp filler panels (7).
nuts that retain the impact bar to the energy absorbers.
bumper.
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Document ID: 298832
Page 2 of 2
Important: Remember the location and the number of shims.

1.
2.
3.
4.
5.
6.
Install the nuts in order to retain the bumper to both sides of the energy absorber.
Install the clips (4) in order to retain the fascia (3) to the taillamp filler panels (7).
Install the nuts (1) in order to retain the fascia to the rear end panel (2).
Install the nuts that retain the fascia to the quarter panels.
Install the screws that retain the wheelhouse extensions to the fascia.
Install the rear compartment side trim. Refer to Rear Compartment Side Trim Replacement Left Side and to Rear Compartment Side Trim Replacement - Right Side .
7. Install the rear compartment sill plate. Refer to Rear Compartment Sill Trim Plate
Replacement .
2/7/2011
Document ID: 298828
Page 1 of 2
Rear Energy Absorber Replacement

Removal Procedure
Caution: Failure to observe the following procedure when handling energy absorbers could
cause personal injury.
Do not apply heat to an energy absorber.
Do not weld in the area of an energy absorber.
Do not attempt to repair a damaged energy absorber. Always replace the damaged
energy absorber with a new part.
If an energy absorber is bound-up as a result of a collision such that it cannot extend,
take precautions to avoid spring-back when bending sheet metal. Provide a positive
restraint, such as a chain or cable to hold the bumper in the position it is in. Wear
approved safety glasses and using a 3mm (1/8 inch) drill bit, drill a small hole in the
piston tube near the bumper bracket to relieve gas pressure. Remove the energy
absorber after gas pressure has been relieved.
If an energy absorber is to be scrapped, relieve the gas pressure prior to disposal of the
part. Make an indentation with a center punch in the small cylinder section of the
energy absorber.
Notice: An energy absorber that has a dislodged blowout plug (due to an above 8 km/h
(5 mph) impact) could have insufficient absorber action in impacts below 8 km/h (5 mph).
Complete diagnosis procedures must be followed after a collision to prevent excessive vehicle
damage in any future low speed impacts.
2. Remove the bumper assembly. Refer to Rear Bumper Replacement .
3. Remove the side rail bolt (4).

4. Remove the followingcomponents:
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Document ID: 298828
Page 2 of 2
The bolts (3)

The nuts (2)
5. Remove the energy absorber (1).
1. Install the energy absorber (1).

2. Install the side rail bolt (4).
Tighten
Tighten the side rail bolt to 4 Nm (35 lb in).
The bolts (3)
The nuts (2)
Tighten
Tighten the bolts and the nuts to 27 Nm (20 lb ft).
4. Install the bumper assembly. Refer to Rear Bumper Replacement .
2/7/2011
Document ID: 298829
Page 1 of 2
Rear Bumper Impact Bar Replacement (Buick)

Removal Procedure
1. Remove the rear bumper. Refer to Rear Bumper Replacement .
2. Remove the push-in retainers (1) that connect the upper fascia support (2) to the rear
impact bar (3).
3. Remove the nuts (5) that retain the fascia stud plates (4).
4. Remove the fascia stud plates (4).
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Document ID: 298829
Page 2 of 2
1. Install the fascia stud plates (4).

2. Install the nuts that retain the fascia stud plates (4).
3. Install the push-in retainers (1) in order to connect the upper fascia support (2) to the rear
impact bar (3).
4. Install the rear bumper. Refer to Rear Bumper Replacement .
2/7/2011
Document ID: 299637
Page 1 of 1
Cruise Control | Specifications | Document ID: 299637

Specification
Application
Metric
English
Cruise Control Module Assembly Nuts
9 Nm
80 lb in
Cruise Control Module to Mounting Bracket Fasteners
7 Nm
62 lb in
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Document ID: 344753
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Cruise Control | Schematic and Routing Diagrams | Document ID: 344753
Cell 34: Multifunction Lever
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Document ID: 344755
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Cruise Control | Schematic and Routing Diagrams | Document ID: 344755
Cell 34: VSS and Stoplamp Switch
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Document ID: 348449
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Cruise Control | Component Locator | Document ID: 348449
Cruise Control Component Views

Left Hand Rear of the Engine Compartment
(1) Windshield Wiper/Washer Module

(2) Cruise Control Module
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Document ID: 346591
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Cruise Control | Component Locator | Document ID: 346591
Cruise Control Connector End Views

Cruise Control Module
12065425
Pin
Wire Color
Circuit No.
Function
GRY
397
DK BLU
84
Cruise Control Set/Coast Switch Signal
GRY/BLK
87
Cruise Control Resume/Accel Switch Signal
PPL
420
BLK
1150
Ground
BRN
1141
Fused Output - IGN3
LT BLU
20
Stoplamp Feed (Pontiac)
WHT
17
Stoplamp Feed (Oldsmobile, Buick)
DK GRN
83
Cruise Control Signal - Disengage
WHT
85
Cruise Control Indicator Lamp Output
DK GRN/WHT
817
Cruise Control ON Switch Output
Brake Pedal Switch Output - TCC
Vehicle Speed Signal
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Document ID: 299638
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Cruise Control | Repair Instructions | Document ID: 299638
Cruise Control Module Replacement

Removal Procedure
1. Remove the injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.
2. Disconnect the cruise control cable (2) from the following components:
The engine bracket
The TBI cam
3. Disconnect the cruise control cable from the module assembly (1).
4. Disconnect the electrical connector from the module assembly.
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Document ID: 299638
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5. Remove the 2 nuts (1) from the mounting studs.

6. Remove the module assembly.
7. Remove the fasteners retaining the module to the mounting bracket.
Remove the module.
1. Install the cruise control module to the mounting bracket.
2. Install the module fasteners.
Tighten
Tighten the fasteners to 7 Nm (62 lb in).
3. Install the module assembly on the mounting studs.

4. Install the 2 nuts (1).
Tighten
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5. Connect the electrical connector to the module (1).

6. Connect the cruise control cable (2) to the module assembly (1).
7. Connect the cruise control cable to the following components:
The engine bracket
The TBI cam
8. Adjust the cruise control cable. Refer to Cruise Control Cable Adjustment .
9. Install the injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.
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Document ID: 299639
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Cruise Control Cable Replacement

Removal Procedure
Important: Note the cable routing for replacement.

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine.
2. Disconnect the cruise control cable from the following components:
The TBI cam (1)
The throttle body bracket (2)
3. Disconnect the cruise control cable from the cruise control module.
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Document ID: 299639
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4. Disconnect the cable from the retainers (2).
1. Connect the cruise control cable to the cruise control module.

2. Install the cruise control cable slug TBI cam (1). Ensure that the cable is under the hook.
3. Snap the cable to the throttle body bracket (2).
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4. Connect the cable to the retainers (2).

5. Adjust the cruise control cable. Refer to Cruise Control Cable Adjustment .
6. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine.
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2/7/2011
Document ID: 299640
Page 1 of 1
Cruise Control Cable Adjustment

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in
Engine Mechanical.
Important: The adjustment lock (1) is located on the TBI end of the cable.
2. Disengage the adjustment lock (1) on the cruise control cable.
When the adjustment lock is disengaged, the cable will move freely in and out of the
adjuster.
3. Hold the TBI at the closed position.
4. Complete the following steps in order to eliminate slack in the cable:
4.1. Pull the cable.
4.2. Engage the adjustment lock.
5. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine
Mechanical.
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Document ID: 299643
Page 1 of 2
Cruise Control Release Switch Replacement

Removal Procedure
Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch

adjustment could cause brake drag and excessive brake lining wear.
1. Remove the left insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.
2. Disconnect the electrical connector.
3. Remove the release switch assembly (1).
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1. Install the release switch assembly (1).

2. Connect the electrical connector.
Important: An incorrect adjustment may cause the cruise control system to work
improperly.
3. Adjust the switch. Refer to Cruise Release Switch Adjustment .
4. Install the left insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console:
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Document ID: 299645
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Cruise Release Switch Adjustment

Connect the brake booster pushrod to the brake pedal assembly before attempting to adjust the
release switch assembly and the stoplamp switch assembly.
Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch

adjustment could cause brake drag and excessive brake lining wear.
1. Press the brake pedal assembly.
2. Insert the following components into the retainers until fully seated against the brake pedal
bracket:
The release switch assembly (1)
The stoplamp switch assembly (2)
3. Twist the switch in order to lock into the desired position.
4. In order to ensure a properly adjusted release switch assembly and a properly adjusted
stoplamp switch assembly, use the following brake pedal assembly travel distances:
The release switch assembly and the stoplamp switch assembly contacts must be open at
a brake pedal travel range of 3.5-12.5 mm (0.125-0.5 in).
The brake pedal assembly travel is measured at the centerline of the brake pedal
assembly pad.
The nominal actuation of the stoplamp switch assembly contacts is about 4.5 mm
(0.188 in) after the cruise control switch assembly contacts close.
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2/7/2011
Document ID: 388901
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Brakes | Disc Brakes |

Specification
Application
Metric
English
Bleeder Valve
13 Nm
110 lb in
Inlet Fitting
45 Nm
33 lb ft
Mounting Bolt
51 Nm
38 lb ft
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2/7/2011
Document ID: 388903
Page 1 of 1
Component Specifications
Specification
Application
Metric
English
64 mm
2.52 in
Discard Thickness. All brake drums and rotors have a discard

dimension cast into them. This is a wear dimension and not a refinish
dimension. Any drum or rotor which does not meet the specification
should be replaced.
30.70 mm
1.209 in
Lateral Runout
0.060 mm
0.002 in
Mimimum Thickness after Refinish
31.08 mm
1.224 in
Caliper Bore Diameter
Rotor Diameter
278.00 mm 10.945 in
Rotor Thickness (Maximum)
32.00 mm
1.260 in
Thickness Variation
0.025 mm
0.001 in
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2/7/2011
Document ID: 388911
Page 1 of 2
Brake Pad Inspection
Inspect the brake linings at regular intervals, and any time the wheels are removed (tire rotation,
etc.) The outer shoe has a wear sensor which makes noise when the linings wear to the point of
requiring lining replacement.
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Document ID: 388911
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When any lining thickness (3) is worn to within 0.76 mm (1/32 in) of the shoe or rivet, replace the
shoe and lining assemblies in axle sets.
When inspecting the disc brakes, check both ends of the outer shoe and lining by looking in at each
end of the caliper. These points are where the highest rate of wear normally occurs. Also, check
the inner shoe lining to make sure that it has not worn prematurely. Look down through the hole in
the top of the caliper to view the inner shoe. Some inboard shoe and linings have a thermal layer
against the shoe, integrally molded with the lining. Do not confuse this extra layer with uneven
inboard-outboard lining wear.
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Document ID: 388912
Page 1 of 3
Brake Pads Replacement

Removal Procedure
2. Remove tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tire
and Wheel.
3. Remove the caliper (1).

4. Remove the outboard shoe and lining (3). Use a screwdriver to disengage the buttons on the
shoe from the holes in the caliper housing.
5. Remove the inboard shoe and lining (2).
1. Before installing new shoes and linings, clean the outside surface of the boot. Use clean,
denatured alcohol.
2. Bottom the piston into the caliper bore. Use a C-clamp over the caliper and piston, tightening
it slowly to press the piston into the bore. Be careful not to damage the piston or the boot.
Important:
The boot must lay flat.
Ensure the convolutions are tucked back into place.
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Document ID: 388912
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3. After bottoming the piston, use a small plastic or wood tool to lift the inner edge of the boot
next to the piston, and press out any trapped air.
4. Connect the inboard shoe and lining by snapping the shoe retainer spring into the piston. The
shoe must lay flat against the piston. After installing the shoe and lining, check that the boot
is not touching the shoe. If it is, remove the shoe and lining and re-seat or re-position the
boot.
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Document ID: 388912
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5. Connect the outboard shoe and lining with the wear sensor at the trailing edge of the shoe
during forward wheel rotation. The back of the show must lay flat against the caliper.
6. Install the caliper.
7. Replace tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tire
and Wheel.
9. Apply approximately 778 N (175 lb) force three times to the brake pedal to seat lining.
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2/7/2011
Document ID: 388913
Page 1 of 1
Brake Pad and Rotor Burnishing

After brake pads have been replaced and/or rotors have been refinished, it is recommended that
the new braking surface be broken in, or burnished. This can be accomplished by making 20 stops
from 48 km/h (30 mph), using medium to firm pedal pressure. Take care to avoid overheating the
brakes.
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2/7/2011
Document ID: 388915
Page 1 of 1
Brake Caliper/Knuckle Maintenance Inspection

Visually check the caliper for fluid leakage through the housing. If the housing is craked or the
casing is leaking, replace the caliper. Also, check for fluid leakage around the pistion area, past the
seal and boot, and service the caliper as needed.
When parts are to be replaced in the caliper, follow the inspection procedures. Refer to Brake
Caliper Overhaul .
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2/7/2011
Document ID: 414093
Page 1 of 4
Brake Caliper Replacement

Removal Procedure
1. Remove two-thirds of the brake fluid from the master cylinder.
2. Raise the vehicle and suitably support. Refer to Raising and Supporting the Vehicle in General
Information.
3. Mark the relationship of the wheel to the axle flange.
4. Remove the wheel and the tire.
5. Re-install two wheel nuts to retain the rotor.
6. If the caliper is to be removed for unit repair, remove the bolt attaching inlet fitting (1), and
plug the opening in the caliper and/or pipe to prevent fluid loss and contamination.
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Document ID: 414093
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7. Push the piston into the caliper bore to provide clearance between linings and rotor.
Install a large C-clamp over the top of the caliper housing and against the back of the
outboard shoe.
Slowly tighten the C-clamp until the piston is pushed into the caliper bore far enough to
slide the caliper off the rotor.
8. Remove the caliper mounting bolts (1) and sleeves.
9. Remove the caliper. If only the shoes and linings are being replaced, suspend the caliper (2)
with a wire hook (1) from the strut.
10. Inspect the mounting bolts and sleeves for corrosion.
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Document ID: 414093
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11. Inspect the bushings for cuts and nicks.

12. If damage is found use new parts when installing the caliper.
13. Do not attempt to polish away corrosion.
Important: Mounting bolts and sleeves should slide through bushings with only hand pressure
applied. If greater force is required, or mechanical assistance is needed, complete the following
steps:
1. Remove the bolts and sleeves along the bushings.
2. Inspect the mounting bores for corrosion. If the bore shows signs of corrosion, remove the
corrosion by using a 1-inch wheel cylinder honing brush.
3. Clean the bores with clean, denatured alcohol.
4. Install bushings and lubricate. Refer to Brake Caliper Overhaul .
1. Liberally coat ID of bushings with silicone grease.

3. Install the mounting bolts and sleeves.
4. Install the inlet fitting, if removed.
Tighten
Tighten the mounting bolts to 51 Nm (38 lb ft)
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Document ID: 414093
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Tighten the Inlet fitting to 45 Nm (33 lb ft).

5. Install the wheel and the tire, aligning the previous mark.
Install the wheel nuts securing the wheel to the hub.
Lower the vehicle.
Torque the wheel nuts per specification in Tires and Wheels.
Tighten
Tighten the wheel nuts to 140 Nm (100 lb ft).
6. Fill the master cylinder to the proper level with clean brake fluid.
Bleed the caliper if the inlet fitting was removed.
Recheck the fluid level.
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Document ID: 414098
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Brake Caliper Inspection

Visually check the caliper for fluid leakage through the housing. If the housing is cracked or the
casing is leaking, replace the caliper. Also, check for fluid leakage around the pistion area, past the
seal and boot, and service the caliper as needed.
When parts are to be replaced in the caliper, follow the inspection procedures. Refer to Brake
Caliper Overhaul .
tomsn048@gmail.com
2/7/2011
Document ID: 388924
Page 1 of 3
Brake Caliper Overhaul

Removal Procedure
Tools Required
J 35777 Caliper Piston Seal Installer.
and Wheel.
3. Remove the caliper (1) from the vehicle.

4. Remove the bushings (6).
Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or
protect it when applying compressed air. The piston(s) can fly out with force and could result
in serious bodily injury.
5. Inspect the bushings for nicks and cuts. Replace the bushings if damaged.
6. Use clean shop towels to pad the interior of the caliper during piston removal.
tomsn048@gmail.com
2/7/2011
Document ID: 388924
Page 2 of 3
7. Remove the piston using compressed air into the caliper inlet hole.
8. Inspect the piston for scoring, nicks, corrosion, and worn or damaged chrome plating.
Replace the piston if any of these are found.
9. Remove the boot. Be careful not to scratch the housing bore.
10. Remove the piston seal from the seal groove in the caliper bore using a small plastic or wood
tool. Do not use a metal tool because this may damage the caliper bore or seal groove.
11. Inspect the caliber bore and seal groove for scoring, nicks, corrosion and wear.
12. Use a crocus cloth to polish out light corrosion. Replace the caliper housing if corrosion in and
around the seal groove will not clean off with a crocus cloth.
13. Remove the bleeder valve cap.
14. Remove the bleeder valve from the caliper.
15. Clean all parts in clean, denatured alcohol.
16. Dry the parts with unlubricated compressed air.
17. Blow out all passages in the caliper housing and bleeder valve.
1. Install the bleeder valve.
2. Install the bleeder valve cap.
Tighten
Bleeder valve cap to 13 Nm (110 lb in)
3. Install the lubricated new piston seal into the caliper bore groove. Make sure the seal
is not
tomsn048@gmail.com
2/7/2011
Document ID: 388924
Page 3 of 3
twisted.
4. Install the lubricated boot into the bore of the caliper. Push the piston to the bottom of the
bore.
5. Using the J 35777 , seat the boot in the caliper housing.
6. Install the bushings.
6.1. Lubricate the beveled end of the bushing with silicone grease.
6.2. Pinch the bushing and install the beveled end first.
6.3. Push the bushing through the housing mounting bore.
7. Install the caliper into the vehicle.
8. Install tire and wheel assembly.
tomsn048@gmail.com
2/7/2011
Document ID: 388927
Page 1 of 1
Brake Rotor Replacement

Removal Procedure
When installing new rotors, do not refinish the new rotors' surface because the rotors are already
at the correct level of finish.
and Wheel.
3. Remove the caliper. Refer to Brake Caliper Replacement .
4. Disconnect the rotor from the hub and bearing assembly.
1.
2.
3.
4.
Position the rotor on the hub and bearing assembly.

Install the caliper. Refer to Brake Caliper Replacement .
Install tire and wheel assembly.
Lower the vehicle.
tomsn048@gmail.com
2/7/2011
Document ID: 388928
Page 1 of 2
Brake Rotor Refinishing

Refinishing Rotors
Do not refinish brake rotors when doing routine maintenance, such as replacing worn disc brake
pads. Refinish a rotor only under the following circumstances:
1. There is a complaint of brake pulsation.
2. There is scoring greater than 1.5 mm (0.060 in)
All brake rotors have a minimum thickness dimension cast into them. This dimension is the
minimum wear dimension and not a refinish dimension. Do not use a brake rotor that, after
refinishing, will not meet the specifications shown on the rotor. Always replace it with a new rotor.
Accurate control of rotor tolerance is necessary for proper performance of the disc brakes.
Machining of the rotor should be done only with precision equipment. Machining equipment should
be serviced on a regular basis following the manufacturer's recommended maintenance
procedures.
When refinishing rotors, the attaching adapters, tool holders, vibration dampeners and tool bits
must be in good condition. Always use sharp cutting tools or bits, and use only replacement cutting
bits recommended by the equipment manufacturer. Dull or worn tools leave a poor surface finish
which will affect braking performance.
Vibration dampening attachments should always be used when refinishing braking surfaces. These
attachments eliminate tool chatter and will result in better surface finish. Make sure these adapters
are clean and free of nicks.
Brake Lathe
It is recommended that an on-vehicle brake lathe be used in cases where rotors are being
refinished to correct a problem with brake pulsation. Follow the equipment manufacturer's
recommended specifications and procedures.
The following are two recommended procedures for using two different off-vehicle drum/disc brake
lathes (if any other lathe is used, follow that lathe's instructions and recommendations.)
When using the AMMCO Brake Lathe:
Spindle Speed:
- Rough cut, 150 rpm
- Finish cut, 150 rpm
Depth of Cut (per side):
- Rough cut, 0.1524--0.6350 mm (0.006--0.025 in).
- Finish cut, 0.1016--0.1524 mm (0.004--0.006 in).
Cross Feed (per rev):
- Rough cut, 0.254 mm (0.010 in).
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2/7/2011
Document ID: 388928
Page 2 of 2
- Finish cut, 0.0508 mm (0.002 in).

Vibration Damper:
- Rough cut-Yes.
- Finish cut-Yes.
When using the ACCU*TURN Brake Lathe, GM Dealer Equipment (one-cut refinishing procedure),
locate the deepest score and turn the rotor micrometer knob until the tool bit bottoms out at the
deepest point of the score. Zero the scale and back out the tool bit (repeat for the opposite side of
the rotor). Advance the cutter handwheel until the bits have cleared the inner edge of the rotor
face. Adjust the micrometer knobs for about 0.127 mm (0.005 inch) more than the first reading.
This will ensure resurfacing of the rotor in one cut.
Spindle Speed: 105 rpm.
Depth of Cut: As necessary.
Cross Feed (per rev): 0.0762 mm (0.003 in).
Tool Bit Nose Radius: 1/64.
Vibration Damper: Yes.
It is very important that the rotor surface be made non-directional by dressing the rotor surfaces
with a sanding disc tool, such as an AMMCO Model 8750 Safe Swirl Disc Rotor Grinder, Accuturn
433179 Non-directional Swirl Finisher, or equivalent, using a 120 grit aluminum oxide sandpaper.
Sand each rotor surface with moderate pressure for a minimum of 60 seconds.
If the brake lathe is not equipped with an adequate non-directional finishing tool, an alternate
method is to use a sanding block with 150 grit aluminum oxide sandpaper. With the rotor turning
at the equipment manufacturer's highest recommended cutting speed, sand each rotor surface for
a minimum of 60 seconds, using moderate pressure.
After the rotor has been sanded, clean each surface with denatured alcohol or a suitable brake
cleaner.
The finished rotor surface should be as close as possible to that of a new rotor. Failure to obtain
the best possible rotor finish may affect braking performance.
After replacing pads and/or refinishing rotors, break in or burnish the new braking surfaces. This
can be done by making 20 stops from 48 km/h (30 mph), using medium to firm pedal pressure.
Take care to not overheat the brakes.
tomsn048@gmail.com
2/7/2011
Document ID: 299978
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories | Doors |

Specification
Metric
English
47 Nm
35 lb ft
6 Nm
54 lb in
Striker Bolts
24 Nm
18 lb ft
Window Run Channel Retaining Bolts
12 Nm
106 lb in
Door Hinge Nuts

Mirror Assembly Retainer Nuts
2/7/2011
Document ID: 344357
Page 1 of 1
Cell 120: Left Power Window Motors - Oldsmobile/Buick
2/7/2011
Document ID: 344398
Page 1 of 1
Cell 130: Door Locks without Keyless Entry, Power Distribution
2/7/2011
Document ID: 344443
Page 1 of 1
Cell 130: Door Locks Without Keyless Entry, Door Lock

Switches
2/7/2011
Document ID: 344446
Page 1 of 1
Cell 130: Door Locks Without Keyless Entry, Door Lock

Actuators
2/7/2011
Document ID: 344448
Page 1 of 1
Cell 130: Door Locks With Keyless Entry - Buick, Oldsmobile
2/7/2011
Document ID: 344454
Page 1 of 1
Cell 130: Door Locks With Keyless Entry - Buick, Oldsmobile,

Pontiac Without UA6
2/7/2011
Document ID: 344466
Page 1 of 1
Cell 147: Buick
2/7/2011
Document ID: 400459
Page 1 of 1
Front Left Side of the Vehicle (Pontiac Shown, Others Similar)
(1) LH Fog Lamp

(2) LH Outside Rear View Mirror
2/7/2011
Document ID: 343429
Page 1 of 2
Left Front Door, Behind the Door Trim
(1) S510
(2) P500
(3) S505
(4) S506
(5) C210
(6) C212
(7) S504
(8) S503
(9) S502
(10) Traction Control Switch( if Equipped)
(11) S501
(12) S500
(13) LH Front Power Window Motor (RH Similar)
(14) Power Window Control Module
(15) C502 (LH) C603 (RH)
(16) C503 (LH) C602 (RH)
(17) C501 (LH) C601 (RH)
(18) LH Front Door Lock Actuator
C2 (RH Similar)
2/7/2011
Document ID: 343429
Page 2 of 2
(19) LH Front Door Lock Actuator C1 (RH Similar)
2/7/2011
Document ID: 343431
Page 1 of 1
Left Hand Rear Door, Behind the Door Trim
(1) LH Rear Power Window Motor (RH Similar)

(2) P700 (LH) P800 (RH)
(3) C 701 (LH) C801 (RH)
(4) C702 (LH) C703 (LH) C802 (RH) C803 (RH)
(5) LH Rear Door Lock Actuator C2 (RH Similar)
(6) LH Rear Door Lock Actuator C1 (RH Similar)
2/7/2011
Document ID: 400536
Page 1 of 1
Passenger Compartment, LH Front Door (Buick/Oldsmobile)
(1) LH Power Door Lock Switch (RH Similar)
2/7/2011
Document ID: 400522
Page 1 of 1
Passenger Compartment, On the Door Armrest
(1) Mirror Switch (Buick)

(2) LH Seat Switch -- RH Similar (Buick)
(3) LH Front Power Window Switch -- RH Similar (Buick)
(4) Mirror Switch (Oldsmobile)
(5) LH Front Power Window Switch -- RH Similar (Oldsmobile)
(6) LH Power Door Lock Switch -- RH Similar (Pontiac)
(7) LH Front Power Window Switch -- RH Similar (Pontiac)
2/7/2011
Document ID: 400604
Page 1 of 1
Passenger Compartment, On the Left Front Door
(1) RH Power Mirror Switch (Pontiac))
2/7/2011
Document ID: 400524
Page 1 of 1
Passenger Compartment, On the Rear Door
(1) LH Rear Power Window Switch (RH Similar)

(2) LH Rear Door Courtesy Lamp (RH Similar)
(3) LH Rear Door Warning Lamp (RH Similar)
2/7/2011
Document ID: 359675
Page 1 of 21
Power Door Systems Connector End Views

Table 1:
LH Front Door Handle Switch (Oldsmobile/Pontiac w/ C97/T2T)
Table 2:
LH Front Door Lock Actuator C1
Table 3:
Table 4:
LH Front Power Door Lock Switch (Oldsmobile, Buick)
Table 5:
LH Front Power Door Lock Switch (Pontiac)
Table 6:
LH Front Power Window Motor
Table 7:
LH Front Power Window Switch (Pontiac)
Table 8:
LH Front Power Window Switch C1 (Buick, Oldsmobile)
Table 9:
Table 10: LH Outside Rearview Mirror C1

Table 11: LH Outside Rearview Mirror C2
Table 12: LH Rear Door Lock Actuator C1
Table 13: LH Rear Door Lock Actuator C2
Table 14: LH Rear Power Window Motor
Table 15: LH Rear Power Window Switch
Table 16: Mirror Switch (Buick)
Table 17: Mirror Switch (Oldsmobile)
Table 18: Mirror Switch (Pontiac)
Table 19: Power Window Control Module
Table 20: RH Front Door Handle Switch (Oldsmobile/Pontiac w/ C97/T2T)
Table 21: RH Front Door Lock Actuator C1
Table 22: RH Front Door Lock Actuator C2
Table 23: RH Front Power Door Lock Switch (Buick/Oldsmobile)
Table 24: RH Front Power Door Lock Switch (Pontiac)
Table 25: RH Front Power Window Motor
Table 26: RH Front Power Window Switch
Table 27: RH Outside Rear View Mirror -- C1
Table 28: RH Outside Rear View Mirror -- C2
Table 29: RH Rear Door Lock Actuator C1
Table 30: RH Rear Door Lock Actuator -- C2
Table 31: RH Rear Power Window Motor
Table 32: RH Rear Power Window Switch
LH Front Door Handle Switch (Oldsmobile/Pontiac

w/ C97/T2T)
2/7/2011
Document ID: 359675
Page 2 of 21
12047663
2 Way M Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit No.
LT GRN/BLK
394
BLK/WHT
1250
Function
Door Handle Switch Signal - Left Front
Ground
12162187
4-Way F Metri-Pak 150.2 Series (BLK)
Pin
Wire Color
Circuit No.
Function
TAN
126
Door Latch Switch Signal - Left Front
YEL
804
Door Ajar Indicator Lamp Output
DK BLU/WHT
727
Door Latch Switch Signal - Secondary
BLK
1250
Ground
2/7/2011
Document ID: 359675
Page 3 of 21
15300008
2-Way F Metri-Pak 280 Series (BLK)
Pin
Wire Color
Circuit No.
Function
TAN
294
Power Door Lock Motor Feed - Unlock
GRA
295
Power Door Lock Motor Feed - Lock
LH Front Power Door Lock Switch (Oldsmobile, Buick)
Connector Part
Information
12124997
Pin
Wire Color
Circuit
No.
ORN/BLK
781
BLK/WHT
1250
RED/BLK
780
GRA
--
--
Not Used
Function
Power Door Lock Switch Output - Driver Door Unlock
Ground
Power Door Lock Switch Output - Driver Switch Lock
LH Front Power Door Lock Switch (Pontiac)
2/7/2011
Document ID: 359675
Connector Part
Information
Page 4 of 21
12047781
Pin
Wire Color
Circuit
No.
ORN/BLK
781
BLK/WHT
1250
RED/BLK
780
Function
Power Door Lock Switch Output - Driver Switch Unlock
Ground
Power Door Lock Switch Output - Driver Switch Lock
LH Front Power Window Motor
Connector Part
Information
12064749
2 Way F Metri-Pack 480 Series (BLK)
Pin
Wire Color
Circuit
No.
DK BLU
164
Power Window Motor Feed - Left Front Window Up
BRN
185
Power Window Motor Feed - Left Front Window Down
Function
2/7/2011
Document ID: 359675
Page 5 of 21
LH Front Power Window Switch (Pontiac)
Connector Part
Information
12010550
10 Way F Pin Grip (BLK)
Pin
Wire Color
Circuit
No.
LT BLU
166
Power Window Master Switch Output - Right Front

Window - Up
TAN
167

Window - Down
DK BLU
164
Power Window Motor Feed - Left Front Window - Up
GRY
1136
Power Window Master Switch Output - Left Front

Window - Down
BLK/WHT
1250
Ground
BRN
141
Fuse Output - Ign 3
LT GRN
170
Power Window Master Switch Output - Right Rear

Window - Up
PPL
171

Window - Down
DK GRN
168
Power Window Master Switch Output - Left Rear

Window - Up
PPL
169

Window - Down
Function
2/7/2011
Document ID: 359675
Connector Part
Information
Page 6 of 21
12010567
10-Way F Pin Grip Connector (BLK)
Pin
Wire Color
Circuit
No.
LT BLU
166

Window - Up
TAN
167

Window - Down
DK BLU
164
Power Window Motor Feed - Left Front Window - Up
GRA
1136
Power Window Master Switch Outout - Left Front

Window - Down
BLK/WHT
1250
Ground
BRN
141
Fuse Output Ignition 3 Type III Fuse
LT GRN
170

Window - Up
PPL
171

Window - Down
DK GRN
168

Window - Up
PPL
169

Window - Down
Function
2/7/2011
Document ID: 359675
Page 7 of 21
12064749
Pin
Wire Color
Circuit No.
BRN
141
DK BLU
1307
Function
Fuse Output - Ign 3
Power Window Master Switch Output - Lockout
LH Outside Rearview Mirror C1
Connector Part
Information
12045688
8 Way M Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit
No.
YEL
88
BLK
1250
LT GRN
89
Power Mirror Motor Feed Left Vertical Motor Down

Direction (Buick)
LT BLU
82
Power Mirror Motor Feed Left Horizontal Motor Left

Direction (Oldsmobile)
GRA
1690
Function
Direction
Ground
Automatic Day/Night Mirror Signal
2/7/2011
Document ID: 359675
Page 8 of 21
BRN
541
WHT
81
PNK
1691
LT BLU
82
Fused Output Ign 3

Power Mirror Motor Feed Left Horizontal Motor Right
Direction
Automatic Day/Night Mirror Return
Direction
LH Outside Rearview Mirror C2
Connector Part
Information
12047786
4-Way M Metri-Pak 150 Series (BLK)
Pin
Wire Color
Circuit
No.
GRA
788
Memory Mirror Position Sensor Feed 5 Volt Ref.
DK GRN
784
Memory Mirror Position Sensor Signal Left Vertical

Motor
BLK
782
Sensor Return Memory Seat/Mirror
GRA/BLK
786
Memory Mirror Position Sensor Signal Left

Horizontal Motor
Function
LH Rear Door Lock Actuator C1
2/7/2011
Document ID: 359675
Page 9 of 21
12162187
4-Way Metri-Pak F 150.2 Series (BLK)
Pin
Wire Color
Circuit No.
Function
WHT
156
Courtesy Lamp Output
BLK/YEL
745
Door Ajar Swicth Signal Left Front
LT BLU
263
Tamper Signal Switch
BLK
150
Ground
LH Rear Door Lock Actuator C2
15300008
Pin
Wire Color
Circuit No.
Function
TAN
294
GRA
295
LH Rear Power Window Motor
2/7/2011
Document ID: 359675
Page 10 of 21
12064749
Connector Part
Information
Pin
Wire Color
Circuit
No.
BRN
669
Power Window Motor Feed Left Rear Window

Down
DK BLU
668
Power Window Motor Feed Left Rear Window Up
Function
LH Rear Power Window Switch
Connector Part
Information
12004879
5 Way F Pin Grip (NAT)
Pin
Wire Color
Circuit
No.
DK BLU
1307
BRN
141
Fused Output - Ign 3 (Pontiac)
PPL
169

Window - Down
DK BLU
668
Power Window Motor Feed - Left Rear Window - Up
BRN
669
Power Window Motor Feed - Left Rear Window - Down
DK GRN
168

Window - Up
Function
Power Window Master Switch Output - Lock Out
(Buick/Oldsmobile)
Mirror Switch (Buick)
2/7/2011
Document ID: 359675
Connector Part
Information
Page 11 of 21
12064862
Pin
Wire Color
Circuit
No.
BLK
1250
LT BLU
82

Direction
YEL
88
Power Mirror Motor Feed Left Vertical Motor Up

Direction
WHT
81

Direction
LT GRN
89

Direction
PPL/ WHT
889
Power Mirror Motor Feed Right Vertical Motor Down

Direction
RED/ WHT
881
Power Mirror Motor Feed Right Horizontal Motor Right

Direction
ORN
640
Fuse Output Battery
Function
Ground
Mirror Switch (Oldsmobile)
2/7/2011
Document ID: 359675
Connector Part
Information
Page 12 of 21
12047886
Pin
Wire Color
Circuit
No.
BRN
1498
Power Mirror Feed Right Vertical Motor Up Direction

(w/o A43)
BRN/WHT
1832
Power Mirror Switch Signal Right Vertical Motor Up

Position (w/ A43)
RED/WHT
881
RED/WHT
1513
Power Mirror Switch Signal Right Horizintal W/ A43
GRY
90
Power Mirror Motor Feed Right Horizontal Motor Left

Direction (w/o A43)
GRY
1831
Power Mirror Switch Signal Right Horizontal Motor Left

Direction (w/ A43)
BLK
1250
Ground
ORN
640
WHT
81
Power Mirror Feed Left Horizintal Motor Right Direction

(w/o A43)
WHT
1512
Power Mirror Switch Signal Left Horizontal Motor Right

Direction (w/ A43)
YEL
88
YEL
1517
LT BLU
82
LT BLU
1516
Function
Power Mirror Motor Feed - Right Horizontal Motor Right

Direction (w/o A43)
Fused Output - Bat
Power Mirror Mootr Feed Left Vertical Motor Up

Direction (w/o A43)
Power Mirror Switch Signal Left Vertical Motor Up
Direction (w/ A43)
Direction (w/o A43)
Power Mirror Switch Signal Left Horizontal Motor Left
Direction (w/ A43)
Mirror Switch (Pontiac)
12045688
Connector Part
2/7/2011
Document ID: 359675
Information
Page 13 of 21
8-Way M Metri-Pak 150 Series (BLK)
Pin
Wire Color
Circuit
No.
ORN
640
WHT
81

Direction
LT BLU
82
Power Mirror Motor Feed Left Horizontal Motor Up

Direction
YEL
88
Power Mirror Motor Feed Right Vertical Motor Up

Direction
BRN/WHT
1498
Power Mirror Motor Feed Right Vertical Motor Up

Direction
GRA
90
Power Mirror Motor Feed Right Horizontal Motor Left

Direction
RED/WHT
881
Powr Mirror Motor Feed Right Horizintal Motor Right

Direction
BLK
1250
Function
Fuse Output Battery
Ground
Power Window Control Module
12048412
4 Way F Metri - Pack 480 Series (BLK)
Pin
Wire Color
Circuit No.
Function
BRN
141
GRY
1136
DK BLU
164
Power Window Motor Feed - Up
BRN
185
Power Window Motor Feed - Down
Fused Output - IGN 3

Power Window Master Switch Output
RH Front Door Handle Switch (Oldsmobile/Pontiac

w/ C97/T2T)
2/7/2011
Document ID: 359675
Page 14 of 21
12047663
2 Way M Metri-Pack 150 Series (GRY)
Pin
Wire Color
Circuit No.
LT GRN
394
BLK
1250
Function
Door Handle Switch Signal-Left Front
Ground
RH Front Door Lock Actuator C1
12162187
4-Way F Metri-Pack 150.2 (BLK)
Pin
Wire Color
Circuit No.
Function
TAN
126
Door Latch Switch Signal Left Front
YEL
804
Door Ajar Indicator Lamp Output
DK BLU/WHT
727
Door Latch Switch Signal Secondary
BLK
1250
Ground
RH Front Door Lock Actuator C2
2/7/2011
Document ID: 359675
Page 15 of 21
15300008
Pin
Wire Color
Circuit No.
Function
TAN
294
Power Door Lock Motor Feed Unlock
GRA
295
Power Door Lock Motor Feed Lock
RH Front Power Door Lock Switch (Buick/Oldsmobile)
Connector Part
Information
12124997
5 Way (BLK)
Pin
Wire Color
Circuit
No.
ORN/ BLK
781
BLK
1250
RED/ BLK
780
GRY
--
--
Not Used
Function
Power Door Lock Switch Output Driver Switch
Unlock
Ground
Lock
2/7/2011
Document ID: 359675
Page 16 of 21
RH Front Power Door Lock Switch (Pontiac)
Connector Part
Information
12047781
Pin
Wire Color
Circuit
No.
ORN/ BLK
781
BLK
1250
RED/BLK
780
Function
Unlock
Ground
Lock
RH Front Power Window Motor
Connector Part
Information
12064749
2-Way Metri-Pack 480 Series (BLK)
Pin
Wire Color
Circuit
No.
DK BLU
666
Function
Power Window Motor Feed - Right Front Window
Up
2/7/2011
Document ID: 359675
BRN
Page 17 of 21
667

Down
RH Front Power Window Switch
Connector Part
Information
12004679
5-Way F Pin Grip (NAT)
Pin
Wire Color
Circuit
No.
DK BLU
1307
BRN
141
Fuse Output Ignition 3 (Pont)
TAN
167

Window Down
DK BLU
666
Power Window Motor Feed - Right Front Window Up
BRN
667

Down
LT BLU
166

Window Up
Function
Power Window Master Switch Output Lockout (Olds &
Buick)
RH Outside Rear View Mirror -- C1
2/7/2011
Document ID: 359675
Connector Part
Information
Page 18 of 21
12045688
8 Way M Metri-Pack 150 Series (GRY)
Pin
Wire Color
Circuit
No.
YEL
88
BRN/ WHT
1498
Power Mirror Motor Feed-Right Vertical Motor-Up

Direction
BLK
1450
Ground
PPL/ WHT
889
Power Mirror Motor Feed-Right Vertical Motor-Down

Direction
GRY
90
Power Mirror Motor Feed-Right Horizontal Motor-Left

Direction
--
--
Not Used
BRN
541
Fused Output - Ign 3
RED/ WHT
881
Power Mirror Motor Feed-Right Horizontal Motor-Right

Direction
--
--
Not Used
LT BLU
82
Power Mirror Motor Feed-Left Horizontal Motor-Left

Direction
GRY
90
Power Mirror Motor Feed-Right Horizontal Motor-Left

Direction
Function
Power Mirror Motor Feed-Left Vertical Motor-Up
Direction
RH Outside Rear View Mirror -- C2
Connector Part
Information
12047786
4-Way M Metric Pack Series 150 (GRY)
Pin
Wire Color
Circuit
No.
Function
GRA
788
Memory Mirror Position Sensor Feed-5 Volt Reference
BRN
787
Memory Mirror Position Sensor Signal - Right Vertical

Motor
2/7/2011
Document ID: 359675
Page 19 of 21
BLK
782
Sensor Return Memory Seat Mirror
LT BLU/BLK
785
Memory Mirror Position Sensor Signal - Right

Horizontal Motor
RH Rear Door Lock Actuator C1
12162187
4-Way F Metri-Pack 150.2 Series (BLK)
Pin
Wire Color
Circuit No.
Function
WHT
156
Courtesy Lamp Output
GRY/ BLK
745
Door Ajar Switch Signal - Left Front
LT BLU
263
BLK
150
Ground
RH Rear Door Lock Actuator -- C2
15300008
Pin
Wire Color
Circuit No.
TAN
294
Function
2/7/2011
Document ID: 359675
Page 20 of 21
GRY
295
RH Rear Power Window Motor
Connector Part
Information
12064749
2-Way F Metric-Pack Series 480 (BLK)
Pin
Wire Color
Circuit
No.
BRN
671
Power Window Motor Feed - Right Rear Window

Down
DK BLU
670
Power Window Motor Feed - Right Rear Window Up
Function
RH Rear Power Window Switch
Connector Part
Information
12004679
5 Way F Pin Grip (NAT)
Pin
Wire Color
Circuit
No.
DK BLU
1307
BRN
141
Function
Power Window Master Switch Output - Lock Out
(Buick/Oldsmobile)
Fuse Output - Ign 3 (Pontiac)
2/7/2011
Document ID: 359675
Page 21 of 21
PPL
171

Window Down
DK BLU
670
Power Window Motor Feed - Right Rear Window Up
BRN
671
Power Window Motor Feed - Right Rear Window Down
LT GRN
170

Window Up
2/7/2011
Document ID: 413698
Page 1 of 3
Front Side Door Window Switch Replacement (Buick)

Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK
position, and all electrical loads must be OFF before servicing any electrical component.
Disconnect the negative battery cable to prevent an electrical spark should a tool or
equipment come in contact with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Remove the two trim panel retaining screw (Oldsmobile).
3. Pull out on the lower pull-handle insert to disengage it from the switch plate (Oldsmobile).
4. Insert a small, flat-blade tool between the switch plate and the trim panel at either the
forward or rearward edge in order to disengage the retainer clips from the trim panel
(Oldsmobile).
5. Remove the switch plate by inserting a small flat-bladed tool between the switch plate and
the trim panel at the forward retaining clip (Buick and Pontiac).
6. Lift the switch plate (1).
2/7/2011
Document ID: 413698
Page 2 of 3
7. Disconnect the electrical connectors (2).

8. Remove the setscrew from the remote mirror control, if applicable.
9. Remove the window switch (1).
1. Install the window switch (2) to the switch plate (1).

2. Install the remote mirror control.
2/7/2011
Document ID: 413698
Page 3 of 3
3. Install the remote mirror set screw.
Tighten
Tighten the setscrew to .8 Nm (7 lb in).
4. Connect the electrical connectors.
5. Install the switch plate (1) in the trim panel.

Push inward the switch plate in order to secure.
6. Connect the negative battery cable.
2/7/2011
Document ID: 413957
Page 1 of 1
Door Lock Switch Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
Disconnect the negative battery cable.

Remove the fastener retaining the switch plate escutcheon to the trim panel.
Use a thin flat-bladed tool to partially remove the switch plate.
Disengage the switch plate retainer clips.
Insert a small, flat-bladed tool between the switch plate and the trim panel.

6. Remove the door lock switch.
1.
2.
3.
4.
5.
Install the door lock switch to the switch plate.

Carefully guide the switch plate in the trim panel.
Ensure the lock rod is aligned properly to the lock rod knob on the switch plate.
Push inward the switch plate in order to secure.
6. Install the retaining fastener.

Tighten
Tighten the fastener to 1.2 Nm (11 lb in).
2/7/2011
Document ID: 400645
Page 1 of 2
Front Side Door Trim Panel Replacement (Buick)

Removal Procedure
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
1. Remove the arm rest bezel switch plate. Refer to Front Side Door Window Switch
Replacement .
2. Use a small, flat-bladed tool.
3. Release the retaining tab on the courtesy lamp.
4. Remove the courtesy lamp. Refer to Door Lamp Replacement
6. Remove the retaining fastener from the rear of the trim panel.
7. Remove the door lock switch bezel. Refer to Door Lock Switch Replacement .
8. Release the trim panel retainers.
Insert the J 38778 between the outer edges of the door trim panel and the door.
9. Lift upward the trim panel.
10. Disconnect the wiring harness from the trim panel.
11. Disconnect the speaker connector, (as necessary).
1. Connect the speaker connector, (as necessary).
2/7/2011
Document ID: 400645
Page 2 of 2
2. Install the wiring harness to the trim panel.

3. Install the trim panel to the door.
Push on the outer edges of the trim panel.
4. Install the door lock switch bezel. Refer to Door Lock Switch Replacement .
5. Install the retaining fastener to the rear of the trim panel.
Tighten
Tighten the fastener to .8 Nm (7 lb in).
6. Connect the courtesy lamp connector.
7. Install the courtesy lamp to the trim panel.
8. Install the 2 retaining fasteners through the switch plate opening.
Tighten
Tighten the two fasteners to 1.8 Nm (16 lb in).
9. Install the switch plate. Refer to Front Side Door Window Switch Replacement .
2/7/2011
Document ID: 400652
Page 1 of 2
Rear Side Door Trim Panel Replacement (Buick)

Removal Procedure
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the switch plate. Refer to Front Side Door Window Switch Replacement .
Remove the retaining fasteners (1) from the switch plate opening.
Disconnect the electrical connectors.
Use a small, flat-bladed tool.
Release the retaining tab on the courtesy lamp.
Partially remove the courtesy lamp.
Disconnect the electrical connector (if equipped).
Remove the retaining fasteners (4) through the courtesy lamp opening.
Remove the door lock switch bezel. Refer to Door Lock Switch Replacement .
Release the trim panel retainers.
Insert the J 38778 between the outer edges of the trim panel and the door.
11. Partially remove the door trim panel.

12. Remove the wiring harness from the trim panel.
13. Remove the door trim panel.
2/7/2011
Document ID: 400652
Page 2 of 2
1. Install the wiring harness to the trim panel.

2. Align the trim panel to the door.
3. Install the door trim panel to the door.
Push inward on the outer edges of the trim panel in order to secure.
4. Install the door lock switch bezel. Refer to Door Lock Switch Replacement .
5. Install the retaining fasteners (4) through the courtesy lamp opening.
Tighten
Tighten the fasteners to 1.8 Nm (16 lb in) in order to secure the rear of the door trim to the
inner panel.
6.
7.
8.
9.
Connect the courtesy lamp electrical connector.

Install the courtesy lamp to the door trim panel.
Push inward on the armrest prior to securing the door trim panel.
Install the retaining fasteners (1) through the switch plate opening.
Tighten
Tighten the fasteners to 1.8 Nm (16 lb in).
10. Install the switch plate. Refer to Front Side Door Window Switch Replacement .
2/7/2011
Document ID: 393771
Page 1 of 2
Door Control Module Replacement

Removal Procedure
2. Remove the trim panel. Refer to Front Side Door Trim Panel Replacement
.
3.
4.
5.
6.
Remove the water deflector. Refer to Door Water Deflector Replacement .

Disconnect the electrical connector (1).
Insert a thin flat-bladed tool between the express down module and the retaining clip.
Remove the express down module (2).
2/7/2011
Document ID: 393771
1.
2.
3.
4.
5.
Page 2 of 2
Install the express down module (2).

Install the water deflector. Refer to Door Water Deflector Replacement .
Install the trim panel. Refer to Front Side Door Trim Panel Replacement .
Connect the negative battery cable.
2/7/2011
Document ID: 482971
Page 1 of 2
Rear Door Energy Absorber Pad Replacement

Removal Procedure
Caution: This vehicle has energy-absorbing foam blocks for side impact protection. To help
avoid personal injury in a collision, foam blocks that are damaged, or removed during repairs
must be replaced. Failure to replace foam blocks that are removed can violate federal law.
1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2. Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
3. Note the wiring harness routing (2) on top of the energy absorbing foam block (1) for reinstallation.
4. Cut (5) the two push pins (4) holding the foam block to the inner door panel.
5. Disconnect the two locking tabs holding the foam block assembly to the door.
6. Move the bottom of the energy absorbing foam block assembly (1) inward and lift upward in
order to remove the foam absorber block.
2/7/2011
Document ID: 482971
Page 2 of 2
1. Install the foam block (1) into the slot in the door module.
2. Push the foam block forward in order to secure the two locking tabs into the inner door
panel.
3. Ensure the tabs are in the lower slot.
Important: New push pins (4) should always be used when installing the foam block
assembly.
4. Install two new push pins (4) in order to secure the foam block (1) to the door.
5. Ensure the new push pins are fully seated.
Important: Ensure that the wiring harness is properly routed and secured to the wiring
harness clip (2) located on top of the energy-absorbing foam block (1).
6. Secure the wiring harness on top of the foam block.
7. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
8. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement
2/7/2011
Document ID: 389038
Page 1 of 2
Door Water Deflector Replacement (Front)

Removal Procedure
1.
2.
3.
4.
Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement
Remove the fasteners from the armrest hanger plates, (if equipped).
Remove the front door armrest hanger plates (if equipped).
Remove the door speakers (if equipped). Refer to Radio Front Side Door Speaker
Replacement in Entertainment.
5. Carefully peel the water deflector off of the inner door panel.
6. Carefully guide the electrical wiring through the slits in the water deflector.
7. Remove the water deflector.
2/7/2011
Document ID: 389038
Page 2 of 2
Notice: Proper sealing is necessary in order to prevent water entry into the door and
possible damage to inner door components.
1.
2.
3.
4.
Align the water deflector to the door.

Carefully guide the electrical wiring through the slits in the water deflector.
Attach the water deflector to the door.
Smooth out the wrinkles in the water deflector beginning with the bottom of the door, then
the sides, then the top.
5. Press the outer edges of the water deflector in order to fasten the water deflector to the
door.
6. Install the armrest hanger plates to the door (if equipped).
7. Install and tighten the fasteners to the hanger plates as follows.
Tighten
1. Buick--Tighten the fasteners to 1.6 Nm (14 lb in).
2. Buick--Tighten the nuts to 8.0 Nm (71 lb in).
3. Pontiac--Tighten the fasteners to 1.8 Nm (16 lb in).
8. Install the door speakers (if equipped). Refer to Radio Front Side Door Speaker Replacement
in Entertainment.
9. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2/7/2011
Document ID: 475771
Page 1 of 2
Rear Side Door Water Deflector Replacement

Removal Procedure
2.
3.
4.
5.
6.
7.
Remove the hanger brackets (1,3) (if equipped).

Partially remove the speaker (if equipped).
Remove the two retainers securing the top of the water deflector (2) to the door.
Carefully peel the water deflector away from the door.
Remove the water deflector (2).
Notice: Proper sealing is necessary in order to prevent water entry into the door and
possible damage to inner door components.
1. Align the water deflector to the door.
2. Ensure the electrical wiring is guided through the slits in the deflector.
2/7/2011
Document ID: 475771
3.
4.
5.
6.
7.
8.
9.
Page 2 of 2
Smooth out the wrinkles in the water deflector.

Ensure that the outer sealing edges of the water deflector are tightly secured to the door.
Install the two retainers at each of the top corners of the water deflector.
Connect the electrical connections to the speaker (if equipped).
Install the speaker (if equipped).
Secure the speaker to the door.
Install the hanger brackets (1,3) to the door (if equipped).
10. Install the hanger bracket fasteners to the door.

Tighten
1. Tighten the fasteners as follows:
2. Buick--Tighten the nuts to 8.0 Nm (71 lb in)
3. Pontiac--Tighten the screws to 1.8 Nm (16 lb in)
4. Pontiac--Tighten the nuts to 8.0 Nm (71 lb in)
11. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2/7/2011
Document ID: 389402
Page 1 of 4
Door Replacement
Adjustment Procedure
1. Adjust the door fore-aft or up-down as follows:
1.1. Ream the stud holes in the pillar side of the hinges with the door and the hinges
removed from the vehicle.
1.2. Reinstall the hinges to the pillar and the door.
Leave the nuts on the pillar side of the hinge loose.
1.3. Reposition the door as needed.
2. Adjust the door in and out by loosening the door mounting fasteners and repositioning the
door as needed.
Tighten
Removal Procedure
1. Mark the location of the upper and lower door hinges (Oldsmobile).
3. Remove the trim panel. Refer to the following procedures:
Front Side Door Trim Panel Replacement
Rear Side Door Trim Panel Replacement
4. Remove the water deflector. Refer to Door Water Deflector Replacement or Rear Side Door
Water Deflector Replacement .
2/7/2011
Document ID: 389402
Page 2 of 4
5. Disconnect all of the electrical connections (2) from the door electrical components.
6. Remove the rubber conduit from the door.
7. Remove the wire harness (2) from the door.

8. Support the door and remove the door mounted nuts.
9. Remove the door, with the aid of an assistant.
1. Install the door to the body, with the aid of an assistant.
2. Inspect the door for proper alignment of the door to the body and the lock-to-striker
engagement.
2/7/2011
Document ID: 389402
Page 3 of 4
3. Adjust the door as needed by loosening the door mounting fasteners and positioning the door
to the desired location.
Tighten
4. Install the wire harness to the door.

5. Install the rubber conduit to the door.
2/7/2011
Document ID: 389402
Page 4 of 4
6. Connect all of the electrical connections (2) to the door electrical components.
7. Install the water deflector. Refer to Door Water Deflector Replacement .
8. Install the trim panel. Refer to the following procedures:
2/7/2011
Document ID: 389476
Page 1 of 3
Door Hinge Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the door. Refer to Door Replacement .

Mark the position of the hinges (1) on the body pillar.
Mark the position of the hinge on the door (2).
Remove the fasteners (3) from the pillar side of the hinge.
Remove the hinge half from the pillar (1).
Important: Be careful to secure the studplate within the door, when removing the hinge half
from the door. The studplate is not attached to the door and could fall into the door.
6.
7.
8.
9.
Check for the location of the studplate.

Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
Remove the hinge fasteners (3) from the door.
Remove the hinge half from the door.
1. Align the hinge half (1) to the body.
2/7/2011
Document ID: 389476
Page 2 of 3
2. Install the hinge to the body fasteners (3).
Tighten
Tighten the fasteners to 47 Nm (35 lb ft).
2/7/2011
Document ID: 389476
Page 3 of 3
3. Align the door half of the hinge with the marks made on the door during removal.
4. Install the hinge to door fasteners.
Tighten
Tighten the fasteners to 47 Nm (35 lb ft).
5. Install the door. Refer to Door Replacement .
Notice: Striker alignment is a crucial part of door latch operation. Do not use the door striker
to adjust the door to the vehicle. Failure to properly adjust the striker can result in damage
to the door latch and the striker.
7. Inspect the door for proper alignment. Adjust the door as needed.
8. Touch up any paint damage to the hinge fasteners with body color paint.
9. Inspect the door alignment.
2/7/2011
Document ID: 528515
Page 1 of 4
Rear Side Door Upper Hinge and Lower Hinge

Replacement
Removal Procedure
1. Remove the door. Refer to Door Replacement .

2. Mark the position of the hinge (1,2) on the body.
3. Remove the hinge to body fasteners.
Important: Be careful to secure the studplate within the door, when removing the hinge half
from the door . The studplate is not attached to the door and could fall into the door.
2/7/2011
Document ID: 528515
Page 2 of 4
4. Remove the door trim panel. Refer to one of the following procedures:
5. Mark the position of the hinge on the door.
6. Remove the hinge to door fasteners (1).
2/7/2011
Document ID: 528515
Page 3 of 4
1. Align the body side half of the hinge (1,2) to the marks made on the pillar during removal.
2. Install the hinge half to the body.
3. Install the fasteners.

Tighten
Tighten the hinge to body fasteners to 35 Nm (26 lb ft).
4. Align the door half of the hinge to the marks made on the door during removal.
5. Install the fasteners (1).
Tighten
Tighten the hinge to door fasteners to 34 Nm (24 lb ft).
6. Touch up any damage to the hinge fasteners (1) with body color paint.
7. Install the door. Refer to Door Replacement .
8. Install the door trim panel. Refer to one of the following procedures:
2/7/2011
Document ID: 528515
Page 4 of 4
2/7/2011
Document ID: 299991
Page 1 of 3
Door Outside Handle Replacement (Buick)

Removal Procedure
Important: Ensure that the window is in the full up position.
2. Remove the door trim panel. Refer to one of the following procedures:
2/7/2011
Document ID: 299991
Page 2 of 3
4. Loosen the two bolts from the door handle.
Important: Be careful when removing the door handle.
5.
6.
7.
8.
9.
10.
Cover the exterior painted surface to avoid scratching the painted surface.
Note the amount of threads showing above the lock rod clips.
Remove the linkage (2).
Discard the lock rod clips.
Remove the fasteners (5).
Remove the door handle (1).
2. If necessary, thread the lock rod into or out of the barrel on the lock rod clip at the lock
assembly in order to ensure the correct amount of threaded area is visible.
3. Install the lock rods to the handle.
4.
5.
6.
7.
Install the handle (1).

Install the two door handle bolts (5).
Apply slight downward pressure on the lock lever. Apply upward pressure on the lock rod.
Hold the lever up. Rotate the barrel nut until the end of the nut aligns with the hole in the
2/7/2011
Document ID: 299991
Page 3 of 3
attaching clip.
8. Install the water deflector. Refer to Door Water Deflector Replacement or Rear Side Door
9. Install the door trim panel. Refer to one of the following procedures:
2/7/2011
Document ID: 389475
Page 1 of 2
Door Inside Handle Replacement

Removal Procedure
4. Remove the door handle rivets.
4.1. Center punch a depression in the head of the rivet.
4.2. Drill out the rivet with a 4 mm (3/16 in) drill bit.
5. Remove the inside remote handle.
Slide the handle rearward in order to disengage the tabs on the handle from the slots in the
door.
6. Remove the handle to the lock rod and the short lock rod from the bellcrank (if equipped).
2/7/2011
Document ID: 389475
Page 2 of 2
1. Install the handle to the lock rod and the short lock rod (if equipped).
2. Install the inside remote handle.

Place the tabs on the handle into the slots in the door and slide the handle forward.
3. Secure the rivets.
Use 4 mm (3/16 in) peel type rivets.
2/7/2011
Document ID: 299997
Page 1 of 2
Door Lock Replacement (Buick)

Removal Procedure
3.
4.
5.
6.
7.
8.

Remove the water deflector. Refer to Door Water Deflector Replacement or Rear Side Door
Remove the lock rods.
Cut out the lock rod clips. Discard the lock rod clips.
Remove the door lock fasteners (2).
Remove the lock mechanism (1).
2/7/2011
Document ID: 299997
Page 2 of 2
1.
2.
3.
4.
5.
6.
Install the new lock rod clips to the lock rods.

Install the lock mechanism (1).
Install the door lock fasteners (2).
Install the lock rods.
Install the water deflector. Refer to Door Water Deflector Replacement or Rear Side Door
2/7/2011
Document ID: 300015
Page 1 of 2
Door Lock Cylinder Replacement (Buick)

Removal Procedure
Important: Ensure that the window is in the full up position.

1.
2.
3.
4.
5.
6.
Tape the window to the header.
Remove the window sash nuts.
Remove the window from the regulator.
Carefully lower the regulator to allow access to the outside door handle.
7.
8.
9.
10.
11.
12.
13.

Disconnect any wire harness (4) that is present.
Remove the three screws from the lock assembly (if applicable).
Disconnect the locking rod retainer.
Remove the locking rod (3).
Remove the lock nut or the retainer (1).
Remove the cylinder (2).
2/7/2011
Document ID: 300015
Page 2 of 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Install the gasket over the cylinder (2), (if supplied).

Install the cylinder (2), including any wire harnesses (4) that may be attached.
Install the lock cylinder nut or retainer (1).
Connect any wire harness (4), if disconnected.
Install the lock rod (3) to the lock assembly.
Install a new lock rod retainer clip if the original clip was damaged or broken.
Install the three screws to the lock assembly (if applicable).
Raise the window regulator in order to install the window.
Install the window to the regulator.
Install the window sash nuts.
Remove the tape that is securing the window.
Adjust the window. Refer to Front Side Door Window Adjustment .
Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .
Verify the door lock operation.
2/7/2011
Document ID: 300018
Page 1 of 2
Door Striker Replacement

Removal Procedure
1. Loosen the striker fasteners (2).

2. Remove the striker (3).
2/7/2011
Document ID: 300018
Page 2 of 2
Caution: Striker alignment is crucial for proper operation of the door systems. Do not hit the
striker with a hammer or force alignment in any other way. Failure to properly adjust striker will
result in excessive door efforts or extensive damage to door system operation which could result in
personal injury.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring replacement or fasteners requiring the use of
thread locking compound or sealant are identified in the service procedure. Do not use paints,
lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These
coatings affect fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in order to avoid damage
Align the striker. Refer to Door Lock Striker Adjustment .
Tighten
Tighten the 2 striker bolts (2) to 24 Nm (18 lb ft).
2/7/2011
Document ID: 300019
Page 1 of 2
Door Lock Striker Adjustment
Notice: Striker alignment is a crucial part of door latch operation. Do not use the door striker
to adjust the door to the vehicle. Failure to properly adjust the striker can result in damage
to the door latch and the striker.
Important: Add or remove the spacers (1) as necessary in order to ensure that the
fastener (2) of the door latch fork is centered on the striker (3) post.
1. Loosen the fasteners (2) from the striker (3).
2/7/2011
Document ID: 300019
Page 2 of 2
2. Tighten the 2 bolts (2) of the striker (3) finger tight. Ensure that the striker (3) moves with
light force.
Tighten
Tighten the bolts of the striker to 24 Nm (18 lb ft).
3. Hold the outside handle out and gently push the door against the body in order to ensure a
flush fit.
4. Unlatch and slowly open the door.
5. Inspect the door for the following conditions:
Fit
Opening effort
Closing effort
6. Repeat steps 1-6 if required.
7. Touch up any exposed or unpainted surface on the lock pillar.
2/7/2011
Document ID: 389479
Page 1 of 1
Front Side Door Window Adjustment
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Ensure that the window is in the full up position.

Remove the trim panel. Refer to Front Side Door Trim Panel Replacement .
Tighten the front run channel bolt in the center of the slot.
Loosen the fasteners that retain the window to the module sash.
Lower the glass 9 cm (3 in).
Slide the glass rearward in the sash fasteners.
Raise the glass.
Tighten the fasteners that retain the window to the module sash.
Cycle the window up and down in order to inspect operation.
2/7/2011
Document ID: 389481
Page 1 of 1
Rear Side Door Window Adjustment

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Ensure that the window is in the full up position.

Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
Loosen the front run channel fasteners.
Loosen the fasteners that retain the window to the module sash.
Slide the glass forward in the sash slots.
Raise the glass.
Tighten the fasteners that retain the window to the module sash.
Tighten the front run channel fasteners.
Cycle the window up and down in order to inspect the operation.
Install the trim panel. Refer to Rear Side Door Trim Panel Replacement .
2/7/2011
Document ID: 393774
Page 1 of 2
Front Side Door Window Module Replacement

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Remove the speaker panel.
Remove the wiring harness retainers.
Tape the glass to the header.
Remove the nuts from the window sash.
Remove the front window channel. Refer to Front Side Door Window Channel Replacement .
Disconnect the rod from the outside door handle.
Disconnect the rod from the lock cylinder.
Remove the three door lock fasteners.
Remove the fasteners from the door module.
Remove the door module (3) with the lock attached.
2/7/2011
Document ID: 393774
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Page 2 of 2
Install the door module (3) with the lock attached.

Install the fasteners to the door module in order to secure.
Instal the fasteners to the door lock.
Connect the rod to the lock cylinder.
Connect the rod to the outside door handle.
Install the fasteners to the window sash.
Install the front window channel. Refer to Front Side Door Window Channel Replacement .
Remove the tape from the glass.
Install the wiring harness retainers.
Install the speaker panel.
Install the door trim panel. Refer to Front Side Door Trim Panel Replacement .
2/7/2011
Document ID: 389478
Page 1 of 3
Rear Side Door Window Module Replacement

Removal Procedure
1. Lower the glass 3 cm (1 in).
2. Disconnect the negative battery cable. Refer to
in Engine Electrical.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Remove the trim panel. Refer to Rear Side Door Trim Panel Replacement .
Remove the hanger plate fasteners (if equipped).
Remove the hanger plates (if equipped).
Remove the water deflector. Refer to Rear Side Door Water Deflector Replacement .
Tape the glass to the header.
Remove the glass sash fasteners.
Remove the outside door handle and lock rod in order to gain better access.
Remove the electrical connectors from the lock.
Remove the trim bracket (if equipped).
12. Cut the push pins (4) securing the energy-absorbing foam block to the inner door panel.
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Document ID: 389478
Page 2 of 3
13. Remove the energy-absorbing foam block.

14. Remove the rear door module fasteners.
15. Remove the rear door module.
1.
2.
3.
4.
Install the rear door module (1) through the access hole.
Install the rear door module fasteners.
Tighten the fasteners finger tight, in order to hold the module in place.
Install the upper trim bracket (if equipped).
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Document ID: 389478
Page 3 of 3
5. Install the energy-absorbing foam block (1).
6. Install new push pin retainers (4) in order to secure the energy-absorbing foam block to the
lower inner door panel.
Important: If the lock rod retainer clips were damaged upon lock rod removal, install new
retainer clips.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Install the lock rods to the lock assembly.

Tighten the fasteners.
Install the outside door handle and lock rod.
Install the glass sash fasteners.
Remove the tape from the door glass and header.
Adjust the window. Refer to Rear Side Door Window Adjustment .
Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
Install the rear door hanger plates.
Install the hanger plate fasteners.
2/7/2011
Document ID: 389457
Page 1 of 3
Power Window Motor Replacement

Removal Procedure
1. Ensure that the window is 3 cm (1 in) below the full up position.
Caution: If this procedure must be done with the regulator out of the vehicle, the
counterbalance spring must be removed first. The regulator lift arms are under tension from
the counterbalance spring and can cause serious injury if the motor is removed without
removing the spring.
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Document ID: 389457
Page 2 of 3
6. Remove the nuts.

7. Remove the actuator (2).
1. Install the actuator (2).

Install the nuts.
2. Connect the electrical connector (3).
2/7/2011
Document ID: 389457
Page 3 of 3
2/7/2011
Document ID: 514547
Page 1 of 4
Door Window Replacement (Front Stationary)

Removal Procedure
1. Lower the window.
3. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
4. Remove the inner door sealing strip. Refer to Front Side Door Window Belt Inner Sealing
Strip Replacement .
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Document ID: 514547
Page 2 of 4
5. Remove the outer door sealing strip. Refer to Front Side Door Window Belt Outer Sealing
Strip Replacement .
6. In order to remove the outer sealing strip, reach over the door and pull upward on the
sealing strip at the securing clip locations.
7. Remove the division post garnish molding.
8. Remove the three retaining screws from the division post.
9. Remove the retainer from the upper rear corner of the glass run channel.
10. Peel the glass run channel from the top edge and the rear (vertical) edge of the door.
11. Pull upward on the forward edge of the glass run channel to disengage the two locator clips.
12. Remove the glass channel from the door.
1.
2.
3.
4.
5.
6.
Beginning with the forward edge, install the glass run channel onto the door.
Secure the locator clips into the slots on the forward edge of the door.
Firmly secure the rest of the glass channel into place, starting at the lower rear corner.
Work your way up the rear (vertical) edge and across the top edge.
Secure the vertical edge first, and then move across the top edge.
Secure the retainer to the upper rear corner of the glass run channel.
7. Install the three retaining screws to the division post.

Tighten
Tighten the three retaining screws in the following sequence to 3 Nm (27 lb in).
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Document ID: 514547
Page 3 of 4
Install the middle screw first.

Tighten
Tighten the middle screw to 3 Nm (27 lb in).
8. Install the top screw second.
Tighten
Tighten the top screw to 3 Nm (27 lb in).
9. Install the bottom screw last.
Tighten
Tighten the bottom screw to 3 Nm (27 lb in).
10. Install the division post garnish molding.
11. Install the outer door sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip
Replacement .
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Document ID: 514547
Page 4 of 4
12. Install the inner door sealing strip. Refer to Front Side Door Window Belt Inner Sealing Strip
Replacement .
15. Power up the window.
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Document ID: 389482
Page 1 of 2
Front Side Door Window Replacement

Removal Procedure
Caution: When working with any type of glass or sheet metal with exposed or rough edges,
wear approved safety glasses and gloves in order to reduce the chance of personal injury.
1.
2.
3.
4.
5.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
trim panel. Refer to Front Side Door Trim Panel Replacement .

water deflector. Refer to Door Water Deflector Replacement .
inner and the outer sealing strips.
sash fasteners (3).
window (1) from the outboard side.
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Document ID: 389482
Page 2 of 2
1.
2.
3.
4.
5.
6.
Install the window from the outboard side (1).

Install the sash fasteners (3).
Install the inner and the outer sealing strips.
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Document ID: 389483
Page 1 of 2
Rear Side Door Window Replacement

Removal Procedure
1.
2.
3.
4.
5.
6.
7.

Remove the trim panel. Refer to Rear Side Door Trim Panel Replacement .
Remove the inner and the outer sealing strips.
Loosen the front channel assembly bolts.
Remove the sash fasteners (2).
Remove the window (1) from the outboard side of the door.
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Document ID: 389483
Page 2 of 2
1.
2.
3.
4.
5.
6.
7.
Install the window (1) from the outboard side of the door.
Install the sash fasteners (2).
Install the inner and the outer sealing strips.
Adjust the window. Refer to Rear Side Door Window Adjustment .
Tighten the front channel assembly upper bolts.
Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
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Document ID: 389471
Page 1 of 2
Rear Side Door Window Channel Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the trim panel. Refer to Rear Side Door Trim Panel Replacement
Remove the two fasteners (2).
Lower the window channel (1) to the bottom of the door.
Remove the window channel through the opening below the door module.
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Document ID: 389471
Page 2 of 2
1. Install the window channel (1).

Tighten
3. Install the water deflector. Refer to Rear Side Door Water Deflector Replacement .
4. Install the trim panel. Refer to Rear Side Door Trim Panel Replacement .
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Document ID: 389472
Page 1 of 2
Front Side Door Window Channel Replacement

Removal Procedure
Caution: Disconnect the power window switch when working inside the driver door. When
operated, the Express Up/Down Feature allows the door window to move very quickly,
without stopping, which could cause personal injury.
1.
2.
3.
4.
5.
6.
7.
Remove the trim panel. Refer to Front Side Door Trim Panel Replacement .
Remove the trim panel brackets (if applicable).
Remove the plastic wiring harness shield.
Remove the window channel fasteners (2).
Move the lower run channel down and to the rear in order to clear the module.
Remove the front window channel.
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Document ID: 389472
Page 2 of 2
1. Install the front window channel.

2. Install the window channel fasteners (2).
Tighten
3.
4.
5.
6.
Install the plastic wiring harness shield.

Secure the shield.
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Document ID: 389473
Page 1 of 2
Front Side Door Window Rear Channel Replacement

Removal Procedure
Caution: Disconnect the power window switch when working inside the driver door. When
operated, the Express Up/Down Feature allows the door window to move very quickly,
without stopping, which could cause personal injury.
1.
2.
3.
4.
5.
Remove the fasteners.
Move the lower window channel (2) downward and to the front.
Remove the window channel (2) through the opening at the front of the door module.
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Document ID: 389473
Page 2 of 2
1. Install the front window channel (2).

2. Place the window channel into approximate position with the wire harness behind the
channel.
3. Line up the window channel on the window and slide the window channel (2) upward in order
to engage the retainer.
4. Push upward and align the lower bracket with the screw hole.
5. Install the fastener.
Tighten
Tighten the fastener to 10 Nm (88 lb in).
6. Install the water deflector. Refer to Door Water Deflector Replacement .
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Document ID: 514546
Page 1 of 3
Rear Side Door Stationary Window Replacement

Removal Procedure
3. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .
4. Remove the inner and outer sealing strips. Refer to Rear Door Window Belt Outer Sealing
Strip Replacement or Rear Door Window Belt Inner Sealing Strip Replacement .
5. Pay close attention not to scratch the painted surface of the door.
6. In order to remove the outer sealing strip, reach over the door and carefully pull upward on
the lower edge of the sealing strip from the front to the rear.
7.
8.
9.
10.
11.
12.
Remove the three retaining screws (1) from the division post (2).
Remove the division post garnish molding (2).
Remove the retainer from the upper forward corner of the glass run channel.
Carefully peel the glass run channel from the forward (vertical) edge from top to the bottom.
Peel the glass run channel from the top edge rearward to the division post.
Push upward and outward at the lower edge of the glass run channel in order to disengage
the locator clips.
13. Remove the glass run channel from the door.
2/7/2011
Document ID: 514546
1.
2.
3.
4.
5.
Page 2 of 3
Install the glass run channel onto the door.

Install the locator clips to the rear edge of the door.
Secure the rest of the glass run channel into place beginning with the lower forward corner.
Work your way up the forward (vertical) edge and across the top edge of the door.
Install the retainer to the upper forward corner of the glass run channel.
6. Install the division post garnish molding (2).

7. Install the three retaining screws to the division post.
8. Install the middle screw first.
Tighten
Tighten the middle screw to 3 Nm (27 lb in).
9. Install the top screw second.
Tighten
Tighten the top screw to 3 Nm (27 lb in).
10. Install the bottom screw third.
Tighten
Tighten the bottom screw to 3 Nm (27 lb in).
11. Install the inner and outer sealing strips. Refer to Rear Door Window Belt Outer Sealing Strip
Replacement or Rear Door Window Belt Inner Sealing Strip Replacement .
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Document ID: 514546
Page 3 of 3
12. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .
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Document ID: 521166
Page 1 of 2
Front Side Door Window Belt Outer Sealing Strip

Replacement
Removal Procedure
1. Remove the outside rearview mirror. Refer to Power Mirror Replacement .
2. Lower the front door window.
3. Remove the front door outer belt sealing strip from the door pinchweld flange.
3.1. Lift upwards, starting at the rear, to disengage sealing strip clips.
3.2. Slide sealing strip rearward to clear the upper auxiliary molding.
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Document ID: 521166
Page 2 of 2
1. Install the front door outer belt sealing strip to the pinchweld flange.
1.1. Align sealing strip to door.
1.2. Slide the strip forward and under upper auxiliary molding.
1.3. Ensure the end cap is flush to door cut line.
1.4. Rotate the sealing strip downward.
1.5. Align sealing strip clips to slots in the door pinchweld flange.
1.6. Push the sealing strip down to fully seat and secure to the door pinchweld flange.
2. Install the outside rearview mirror. Refer to Power Mirror Replacement .
3. Raise the front door window.
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Document ID: 521170
Page 1 of 2
Rear Side Door Window Outer Sealing Strip

Replacement
Removal Procedure
1. Lower the rear door window.
2. Remove rear door outer belt sealing strip from the rear door pinchweld flange, by gently
pulling up, being careful not to distort the strip.
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Document ID: 521170
Page 2 of 2
1. Install the rear door outer belt sealing strip to the rear door pinchweld flange .
1.1. Align the sealing strip clips to the slots in the pinchweld flange of the door.
1.2. Push the sealing strip down to fully seat and secure the strip to the door.
2. Raise the rear door window.
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Document ID: 521174
Page 1 of 2
Front Side Door Window Belt Inner Sealing Strip

Replacement
Removal Procedure
1. Lower the window all the way down.

2. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Starting at one end of the window inner belt molding, pull upward to release the molding.
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Document ID: 521174
Page 2 of 2
1. Position the door window inner belt molding over the flange of the door inner panel.
2. Press down, being careful not to distort the molding, in order to engage the door window
inner belt molding the entire length of the door.
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Document ID: 521175
Page 1 of 2
Rear Side Door Window Inner Sealing Strip

Replacement
Removal Procedure

3. Starting at one end of the door window inner belt molding pull upward in order to release the
molding.
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Document ID: 521175
Page 2 of 2
1. Position the door window belt molding over the flange of the door inner panel.
2. Position the notch in the belt molding to the rear stationary window frame.
3. Press down in order engage the door window inner belt molding the entire length, being
careful not to distort the belt molding.
4. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
2/7/2011
Document ID: 389407
Page 1 of 1
Door Weatherstrip Replacement

Removal Procedure
1.
2.
3.
4.
Open the door either front or rear.

Peel the weatherstrip from the flange.
Remove the screws from the auxiliary (dogleg) weatherstrip (rear door only).
Remove the auxiliary weatherstrip.
1.
2.
3.
4.
Align the weatherstrip to the door and press the weatherstrip to the flange in all directions.
Install the auxiliary weatherstrip (rear door only).
Install the screws to the rear door auxiliary weatherstrip in order to secure.
Close the doors.
2/7/2011
Document ID: 300025
Page 1 of 2
Power Mirror Replacement

Removal Procedure
2. Remove the trim panel. Refer to Front Side Door Trim Panel Replacement .
3. Remove the water deflector. Refer to Door Water Deflector Replacement .
4. Disconnect the wire connectors (1).

5. Remove the fasteners (2).
6. Remove the mirror assembly (3).
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Document ID: 300025
Page 2 of 2
1. Install the mirror assembly (3) to the door.

Tighten
3.
4.
5.
6.
Connect the wire connectors (1).

2/7/2011
Document ID: 389366
Page 1 of 3
Mirror Face Replacement - Outside Electrochromatic

Removal Procedure
1. Remove the mirror and plastic backing plate (7) by pulling the assembly out of the mirror
housing (1).
2. Verify that the springs (5) on the actuator shafts are not pushed down on the shafts.
3. Ensure that the springs (5) are seated in the grooves.
2/7/2011
Document ID: 389366
Page 2 of 3
1. Snap the actuator shafts into the power drive unit (8).
3. Rotate the actuator shafts in order to align the ears with the corresponding slots in the back
side of the mirror face (7).
4. Align the swivel (3) on the power drive unit (8) to the pivot points on the mirror backing
plate.
Notice: To avoid damaging electrochromic mirrors, yellowing and/or silver delamination,
pressure must not be applied to the center of the mirror. Place a 6 x 9 cm (2 x 3 in) block of
wood in the indicated target area. This will distribute pressure evenly.
5. Hold a block against the mirror face while you perform the following procedure:
5.1. Push in on the block (6) until you hear an audible click.
5.2. Tilt the mirror (7) toward the upper actuator shaft (2).
Apply pressure on the block until the ratchet sound stops.
5.3. Tilt the mirror (7) toward the outside actuator shaft (4).
Apply pressure on the block until the ratchet sound stops.
6. Inspect the mirror for proper operation.
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Document ID: 389366
Page 3 of 3
If the mirror is not operating properly, inspect the actuator shaft alignments again.
2/7/2011
Document ID: 391679
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Brakes | Drum Brakes |

Specification
Application
Metric
English
Bleeder Valve
10 Nm
88 lb in
Brake Pipe to Wheel Cylinder
15 Nm
11 lb ft
Hub and Bearing Bolt
70 Nm
52 lb ft
Wheel Cylinder to Backing Plate Bolt
12 Nm
106 lb in
140 Nm
100 lb in
Wheel Nuts
tomsn048@gmail.com
2/7/2011
Document ID: 391680
Page 1 of 1
Specification
Application
Metric
English
Discard Diameter
226.30 mm
8.909 in
Inside Diameter
225.12 mm
8.863 in
Maximum Refinish Diameter
225.54 mm
8.879 in
0.15 mm
0.006 in
23.80 mm
0.937 in
Runout
Wheel Cylinder Bore
All brake drums and rotors have a discard dimension cast into them. This is a wear
dimension and not a refinish dimension. Replace any drum or rotor which does not meet the
specification.
tomsn048@gmail.com
2/7/2011
Document ID: 391686
Page 1 of 2
Brake Drum Inspection

Pulsations in the brake pedal can usually be corrected by servicing the front disc brakes. Service
the rear drum brakes only if the problem persists.
In order to determine if the front or rear brakes are at fault, test drive the vehicle at a low speed in
an area away from people and moving traffic, such as a large parking lot. Apply the parking brake
and feel for pulsation. The park brake is a push to release style, it may be necessary to push the
park brake twice while performing this procedure if the latching mechanism is reached. If a
pulsation is not noticed, the fault is probably in the front brakes.
When the brake drums are removed, thoroughly clean and inspect the brake drums for cracks,
scores, deep grooves, being out-of-round and taper. Replace a cracked drum; it is unsafe for
further use. Do not weld a cracked drum.
Surface Finish
Normal, light scoring of drum surfaces less than 1.5 mm (1/16 in) deep is not detrimental to brake
operation. Smooth out any light scores. Heavy or extensive scoring will cause excessive lining
wear, and resurfacing the drum braking surface might be necessary.
If the linings are slightly worn (but still usable) and the drum is grooved, polish the drum with a
fine emery cloth; do not refinish it. Eliminating all drum grooves and smoothing the lining ridges
would require removing too much metal and lining. If left alone, the grooves and ridges match and
satisfactory service can be obtained. If brake linings are to be replaced, refinish a grooved drum. If
a grooved drum is used with new lining, it will wear the lining, making proper brake performance
difficult to obtain.
Inside Diameter Check

The inside diameter should be checked for conformance to the following specifications, and to
determine if refinishing is possible. The drum has a discard dimension cast into it, which is a wear
dimension and not a refinish dimension. If the drum does not meet specifications, it should be
replaced. Refer to Component Specifications .
Taper Check
An out-of-round or tapered drum prevents accurate brake shoe adjustment, and is likely to cause
excessive wear of other brake parts due to its eccentric action. An out-of-round drum can also
cause severe and irregular tire tread wear, as well as causing the brake pedal to pulsate.
When a drum exceeds specification limits in taper and/or out-of-round, refinish the drum to true up
the braking surface. Out-of-round, as well as taper and wear, can be accurately measured with an
inside micrometer and extension rods. When measuring the drum, take measurements at the open
and closed edges of the machined surface and at right angles to each other.
Runout Check
a brake
A runout check can be done along with taper/out-of-round checks. It can also be done ontomsn048@gmail.com
2/7/2011
Document ID: 391686
Page 2 of 2
lathe, using a dial indicator to check the inside of the drum. Runout specifications are 0.15 mm
(0.006 in).
Balance
During manufacturing, weights are used to balance brake drums; do not remove these weights.
After refinishing drums, or when maintaining wheel balance is difficult, check the drums for
balance. They can be checked on most off-vehicle balancers. If found to be out of balance, replace
the drum.
tomsn048@gmail.com
2/7/2011
Document ID: 391694
Page 1 of 2
Brake Drum Replacement

Removal Procedure
Important: While installing a new brake drum, do not refinish the braking surface, as it is
already at the correct level of finish.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Mark the relationship of the wheel to the wheel studs in the bearing flange.
4. Mark the relationship of the drum to the wheel studs in the bearing flange.
Notice: Do not pry against the splash shield which surrounds the backing plate in an attempt
to free the drum. This will bend the splash shield.
5. Remove the brake drum (1). If the drum is difficult to remove, use the following procedure:
5.1. Make sure the parking brake is released.
5.2. Back off the parking brake cable adjustment.
5.3. Use a hammer and a small metal punch to bend in the backing plate knockout slug to
provide access to the park brake lever.
5.4. Insert the metal punch or a screwdriver through the hole and press in to push the park
brake lever off its stop. This lets the shoe and linings retract slightly.
5.5. Apply a small amount of penetrating oil around the drum pilot hole.
Important: After the drum has been removed from the vehicle, be sure to remove the
knockout slug, using pliers or vise grips. Then insert a rubber access hole plug (service part)
into the hole to prevent dirt or contamination from entering the drum brake assembly.
tomsn048@gmail.com
2/7/2011
Document ID: 391694
Page 2 of 2
6. Before installing brake drum and wheel, adjust the following items:
The service brakes.
Refer to Drum Brake Adjustment .
The parking brake.
Refer to Park Brake Cable Service/Adjustment .
1. Install the brake drum, aligning the marks made at the removal.
2. Install the wheel and the tire, aligning the marks made at the removal.
4. Tighten the wheel nuts.
Tighten
tomsn048@gmail.com
2/7/2011
Document ID: 391700
Page 1 of 1
Brake Drum Refinishing

When refinishing the drum, remove only enough metal to obtain a true, smooth braking surface.
Replace the drum if it does not clean up when refinished to a maximum refinish diameter, as
directed in the Specifications. Removal of more metal will affect the heat dissipation and may cause
a drum distortion.
The brake drums have a maximum diameter cast into them. This is the maximum wear diameter
not a refinish diameter. Do not refinish a drum which does not meet the Specifications. Replace the
drum if this occurs.
When refinishing a brake drum, resurface the drum to a dimension no more than 0.76 mm
(0.030 in) less than the discard diameter. The refinish diameter is the maximum diameter to which
the drum may be refinished and still provide safe braking. If the dimension is exceeded, the drum
will wear beyond the discard diameter during normal brake wear.
Always use sharp cutting tools or bits. Use only replacement cutting bits recommended by the
equipment manufacturer. Dull or worn tools leave a poor surface finish which will affect the initial
braking performance.
Always use vibration dampening attachments to prevent tool chatter and a better surface can be
obtained.
When refinishing a brake drum, the following is recommended:
Optimum spindle speed: 200 rpm.
Cross feed (per rev):
- Rough cut, 0.25 to 0.15 mm (0.010 to 0.006 in).
- Finish cuts 0.05 mm (0.002 in), maximum.
tomsn048@gmail.com
2/7/2011
Document ID: 391705
Page 1 of 1
Brake Shoe Inspection

Inspect the rear brake shoes every 6,000 miles and any time the wheels are removed (tire
rotation, etc.). Inspect the rear brake shoes for wear by removing the rear brake drum. Replace
the rear brake shoes when the thickness is worn to within 0.76 mm (0.030 in) of the shoe or rivet
head. Always replace the rear brake shoes as a complete axle set.
tomsn048@gmail.com
2/7/2011
Document ID: 391707
Page 1 of 9
Brake Shoe Replacement

Removal Procedure
Tools Required
J 38400 Brake Shoe Spanner and Spring Remover
Caution: Keep fingers away from rear brake shoe springs to prevent fingers from being
pinched between spring and shoe web or spring and backing plate.
Notice: Do not pry against the splash shield or backing plate in attempt to free the drum.
This will bend the splash shield or backing plate. A bent backing plate may cause brake
chatter and/or pulsation.
Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over
stretched.
Information.
2. Mark the relationship of the wheel to the axle flange.
3. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Mark the relationship of the drum to the axle flange.
5. Remove the brake drum. If difficulty is encountered in removing the brake drum, the
following steps may be of assistance:
5.1. Remove the retainer clip
5.2. Verify that the parking brake is released
5.3. Back off the parking
brake
cable
adjustment
General
Motors
Corporation. All rights reserved.
2011
tomsn048@gmail.com
2/7/2011
Document ID: 391707
Page 2 of 9
5.4. Remove the access hole plug from the backing plate (1)
5.5. Use a flat bladed tool (2) in order to back off the adjusting screw
5.6. Reinstall the access hole plug in order to prevent dirt or contamination from entering
the drum brake
5.7. Apply a small amount of penetrating oil around the drum pilot hole
6. Remove the adjuster spring (1). Use the J 38400 in order to pry the loop end of the adjuster
spring from the adjuster actuator. Then disengage the adjuster spring from the web of the
parking brake shoe.
7. Remove the lift end of the return spring (2) from the adjuster shoe and the lining (1).
8. Insert the hook end of the J 38400 between the return spring and the adjuster shoe web.
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2/7/2011
Document ID: 391707
Page 3 of 9
9. Pry or twist the J 38400 in order to lift the end of the spring (2) out of the shoe web hole.
10. Pry the end of the return spring (2) toward the axle with the flat edge of the J 38400 until
the return spring snaps down off the shoe web onto the backing plate.
tomsn048@gmail.com
2/7/2011
Document ID: 391707
Page 4 of 9
11. Remove the adjuster actuator (1) from the following components:
The brake shoe
The brake lining (4, 5)
The adjusting screw (2)
12. Remove the parking brake lever (3) from the parking brake shoe and the parking brake
lining. Do not remove the parking brake cable from the parking brake lever unless the
parking brake lever is to be replaced.
13. Lift the end of the return spring (2) from the parking brake shoe and the parking brake lining
(1). Insert the hook end of the J 38400 between the return spring and the parking brake
shoe web. Pry or twist the J 38400 in order to lift the end of the spring out of the shoe web
hole.
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2/7/2011
Document ID: 391707
Page 5 of 9
14. Pry the end of the return spring (2) toward the axle with the flat edge of the J 38400 until it
snaps down off the shoe web onto the backing plate.
15. Remove the parking brake shoe and the parking brake lining.
16. Remove the return spring from the backing plate. If only the shoes and linings are being
replaced, do not remove the return spring.
17. Clean all parts in clean denatured alcohol.
18. Inspect and replace any parts that are of doubtful strength or quality due to the following
conditions:
Discoloration from heat
Over stress
The parts are worn
19. Inspect the wheel cylinder for the following conditions:
Leakage
Cut or damaged boots
20. Do not attempt to repair the wheel cylinder. Replace the wheel cylinder, refer to Wheel
Cylinder Replacement .
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2/7/2011
Document ID: 391707
Page 6 of 9
Important: Lubricate the following components with GM P/N 1052196 or equivalent brake
lubricant:
The six raised shoe pads on the backing plate
The anchor surfaces on the backing plate. The anchor surfaces contact the lower ends
of the brake shoes.
1. Reinstall the hooking center spring section under the tab on the anchor, if the return spring
was removed.
2. Install the parking brake shoe and lining. Position the shoe and the lining on the backing
plate.
3. Use the J 38400 in order to pull up the end of the return spring (2), resting the return spring
on the web of the brake shoe (1).
4. Use the J 38400 in order to pull the end of the return spring over until the return spring
snaps in the slot in the brake shoe.
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2/7/2011
Document ID: 391707
Page 7 of 9
5. Connect the parking brake lever (3) to the parking brake shoe and lining (4).
6. Connect the parking brake cable to the parking brake lever, if disconnected.
7. Before reinstallation, disassemble, thoroughly clean and lubricate the adjusting screw (2) in
the following manner:
Clean the adjuster screw threads with a wire brush.
Wash all components in clean denatured alcohol.
Apply GM P/N 1052196 or equivalent brake lubricant to the following areas:
The adjuster screw threads
The inside the diameter of the adjuster socket
The socket face
Adequate lubrication is achieved when a continuous bead of lubricant is on the end of
the adjuster nut and the socket when the threads are fully engaged
8. Inspect the threads of the adjuster screw for smooth rotation over the full length.

The adjusting screw (2)
The adjuster shoe
The adjuster shoe lining
Engage the adjuster nut end of the adjusting screw (2) with the web of the parking brake
shoe and lining and the parking brake lever (3)
Position the adjuster shoe and lining so that the shoe web engages the deep slot in the
socket end of the adjusting screw
10. Install the return spring into the adjuster shoe and lining.
10.1. Use the J 38400 in order to pull up the end of the return spring, resting the return
spring on the web of the brake shoe.
10.2. Use the J 38400 in order to pull the end of the return spring over until the return
spring snaps in the slot in the brake shoe.
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2/7/2011
Document ID: 391707
Page 8 of 9
11. Install the adjuster actuator.

11.1. Lubricate the tab and the pivot point on the adjuster lever with GM P/N 1052196 or
equivalent brake lubricant.
11.2. Use the J 38400 in order to spread the brake shoes while working the adjuster
actuator (1) into position.
12. Install the adjuster spring.
12.1. Engage the U-shaped end of the spring in the hole in the web of the parking brake
shoe.
12.2. Use the J 38400 in order to stretch the spring and engage the loop end over the tab
on the adjuster actuator.
13. Note the following items in order to ensure the proper positioning and function of the
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2/7/2011
Document ID: 391707
Page 9 of 9
adjuster actuator:
The adjuster actuator (8) pivots in the shoe web slot
The notch in the adjuster actuator rests on the step in the adjusting screw (2) notch
The arm of the adjuster actuator rests freely on the star wheel teeth of the adjuster
screw, not trapped under the teeth in a downward angle
Use the J 38400 between the upper ends of the shoe and lining assemblies. Spread the
shoes apart and watch for proper rotation of the star wheel
14. Adjust the brakes. Refer to Drum Brake Adjustment .
15. Adjust the parking brake.
For the drum brakes, refer to Park Brake Cable Service/Adjustment in Park Brake.
16. Install the brake drums. Align the marks made during removal.
17. Install the tires and the wheels. Align the marks made during removal. Refer to Tire and
Wheel Removal and Installation in Tires and Wheels.
tomsn048@gmail.com
2/7/2011
Document ID: 391710
Page 1 of 1
Brake Backing Plate Replacement

Removal Procedure
Information.
2. Remove the brake drum and components. Refer to Brake Drum Replacement .
3. Disconnect the brake pipe from the wheel cylinder.
4. Disconnect the park brake cable from the backing plate.
5. Remove the hub and bearing bolts. Refer to Rear Wheel Bearing and Hub Replacement in
Rear Suspension.
6. Remove the backing plate.
1. Install the backing plate.
2. Install the hub and bearing with bolts. Refer to Rear Wheel Bearing and Hub Replacement in
Rear Suspension.
3. Connect the park brake cable to the backing plate.
4. Connect the brake pipe to the wheel cylinder. Tighten the brake pipe fitting (tube nut).
Tighten
Tighten the brake pipe fitting to 15 Nm (11 lb ft).
5. Install the brake drum and components. Refer to Brake Drum Replacement .
6. Bleed the brake hydraulic system. Refer to Hydraulic Brake System Bleeding in Hydraulic
Brakes.
7. Adjust the service brakes. Refer to Brake Drum Replacement .
8. Adjust the parking brake. Refer to Park Brake Cable Service/Adjustment in Park Brakes.
10. Check for proper brake operation.
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2/7/2011
Document ID: 391712
Page 1 of 2
Wheel Cylinder Replacement

Removal Procedure
1. Clean the area around the wheel cylinder inlet, the pilot and the bleeder valve.
2. Remove the brake drum. Refer to Brake Drum Replacement .
3. Remove the brake components, as needed for access.
4. Remove the bleeder valve (1).

5. Disconnect the brake pipe from the wheel cylinder. Plug the opening in the pipe to prevent
fluid loss and contamination.
7. Remove the wheel cylinder (3).
8. Clean the old sealant from the backing plate where the wheel cylinder was removed.
9. Clean the sealant from the wheel cylinder (if the wheel cylinder is to be reinstalled).
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2/7/2011
Document ID: 391712
Page 2 of 2
1. Apply Loctite Master Gasket or equivalent to the wheel cylinder shoulder face that contacts
the backing plate.
2. Position the wheel cylinder and hold it in place.
3. Install the bolts.
Tighten
Tighten the attaching bolts to 12 Nm (106 lb in).
4. Connect the brake pipe to the wheel cylinder.
Tighten
Tighten the brake pipe fitting (tube nut) to 15 Nm (11 lb ft).
5. Install the bleeder valve.
Tighten
Tighten the bleeder valve to 10 Nm (88 lb in).
6. Install the brake components.
7. Install the brake drum. Refer to Brake Drum Replacement .
8. Bleed the wheel cylinder. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
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2/7/2011
Document ID: 391715
Page 1 of 1
Drum Brake Adjustment

Tools Required
J 21177-A Drum to Brake Shoe Clearance Gauge
Information.
2. Mark the relationship of the wheel to the wheel studs in the bearing flange.
3. Remove the rear wheels and tires. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
4. Mark the relationship of the drum to the wheel studs in the bearing flange.
5. Remove the brake drum. Refer to Brake Drum Replacement .
6. Ensure the lever stops on both park brake levers are against the edges of the shoe webs on
the park brake shoes. If the park brake cable is holding the stops off of the edge of the shoe
web, loosen the park brake cable adjustment.
7. Measure the inside diameter (ID) of the drum using the J 21177-A .
8. Turning the star wheel on the adjusting screw assembly, adjust the shoe and lining diameter
to 1.27 mm (0.050 in) less than the drum ID.
9. Install the drum and wheel, aligning the marks that were made during the removal.
10. Repeat steps 2 through 9 in order to adjust the other rear brake position.
11. Torque the wheel nuts.
Tighten
Tighten the wheel nuts to 140 Nm (100 lb in).
13. Apply and release the service brake pedal 30 to 35 times with normal pedal force. Pause
about one second between pedal applications.
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2/7/2011
Document ID: 215946
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre, LSS (VIN C/H) Service Manual | Engine | Engine Cooling |

Specification
Application
Metric
English
Coolant Recovery Reservoir
13 Nm
10 lb ft
Fan Attaching Bolts
10 Nm
89 lb in
Radiator Upper Tie Bar Bolt
10 Nm
89 lb in
Water Pump Mounting Long Bolts
30 Nm
22 lb ft
Water Pump Mounting Short Bolts
15 Nm
11 lb ft
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Document ID: 218402
Page 1 of 1
Cooling Fan Schematics

Cell 31: Cooling System
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Document ID: 232212
Page 1 of 1
Front of Engine Compartment
(1) RH Engine Cooling Fan Motor

(2) LH Engine Cooling Fan Motor
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Document ID: 548195
Page 1 of 1
Rear of the Engine Compartment
(1) Battery Positive Cable Connection

(2) LH Underhood Fuse Block
(3) Low Speed Engine Cooling Fan Relay
(4) High Speed Engine Cooling Fan Relay
(5) High Blower Relay
(6) Blower Motor Relay
(7) Horn Relay
(8) A/C Clutch Relay
(9) RH Underhood Fuse Block
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Document ID: 234239
Page 1 of 3
Cooling System Connector End Views

LH Engine Cooling Fan Motor
12085030
2-Way F Metri-Pack 630 Series, Sealed (BLK)
Pin
Wire Color
Circuit No.
Function
LT BLU
409
Cooling Fan Motor Feed
GRY
532
Cooling Fan Motor Feed - Secondary
BLK
1150
Ground
High Speed Engine Cooling Fan Relay
12129716
4-Way F Metri-Pack, Flex-Lock, Sealed (GRY)
Pin
Wire Color
Circuit No.
30
RED
742
Function
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Document ID: 234239
Page 2 of 3
85
BRN
241
Fused Output IGN3
86
DK BLU
473
Cooling Fan Relay Output - Coil - Secondary
87
GRY
532
Cooling Fan Motor Feed - Secondary
Low Speed Engine Cooling Fan Relay
Connector Part
Information
12129716
4-Way F Metri-Pack 280 Series, Flex Lock, Sealed
(GRY)
Pin
Wire Color
Circuit No.
Function
30
RED
742
85
BRN
241
Fused Output - IGN3
86
DK GRN
335
Cooling Fan Relay Output - Coil
87
LT BLU
409
RH Engine Cooling Fan Motor

Pin
Wire Color
12103172
Circuit No.
Function
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Document ID: 234239
Page 3 of 3
BLK
1150
LT BLU
409
Ground
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Page 1 of 2
Cooling System Draining and Filling

Draining Procedure
Caution: As long as there is pressure in the cooling system, the temperature can be considerably
higher than the boiling temperature of the solution in the radiator without causing the solution to
boil. Removal of the pressure cap while the engine is hot and pressure is high will cause the
solution to boil instantaneously -- possibly with explosive force -- spewing the solution over the
engine, fenders and the person removing the cap.
1. Completely drain the cooling system by opening the radiator drain cock at the bottom of the
radiator.
2. If the coolant is dirty, or if there are deposits in the radiator, flush the cooling system before
refilling. Refer to Flushing .
3. Remove the radiator pressure cap.
3.1. Clean the cap.
3.2. Test the cap. Refer to Pressure Cap Testing
3.3. If necessary, replace the cap.
3.4. Clean the radiator filler neck. Inspect the filler neck.
4. Disconnect the hose from the coolant recovery reservoir. Remove the reservoir. Refer to
Coolant Recovery Reservoir Replacement .
4.1. Clean the outside of the coolant recovery reservoir.
4.2. Pour out any fluid.
4.3. Thoroughly clean the inside of the reservoir using soap and water.
4.4. Thoroughly flush the reservoir with clean water. Drain the reservoir.
5. Install the reservoir. Connect the reservoir hose. Refer to Coolant Recovery Reservoir
Replacement .
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Page 2 of 2
Filling Procedure
1. Refill the cooling system with GM Goodwrench DEX-COOL or Havoline DEX-COOL. To
ensure sufficient engine cooling, freezing and corrosion protection, maintain the protection
level at -37C (-34F) lower. Use a solution that is no more than 70 percent antifreeze.
2. Place the heater and A/C control in any A/C mode except Max and the temperature in the
highest setting.
3. Allow the engine to continue idling until the lower radiator to coolant pump hose is hot.
4. Cycle the engine speed up to about 3000 rpm and back to idle five times. Slowly open the
bleed valve on the rear of the thermostat housing for approximately 15 seconds to expel any
trapped air in the cooling system.
5. After the air has been expelled, fill the radiator. Install the radiator pressure cap, making
sure the arrows on the cap line up with the coolant recovery tube.
6. Allow the engine to cool to outside temperature. Check the coolant level in the reservoir.
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Document ID: 214680
Page 1 of 1
Flushing
Various methods and equipment may be used to flush the system. If using special equipment such
as a back flusher, follow the manufacturer's instructions. However, the thermostat should be
removed before flushing the system.
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Document ID: 215950
Page 1 of 2
Coolant Recovery Reservoir Replacement

Removal Procedure
1.
2.
3.
4.

Disconnect the positive battery cable.
Remove the battery.
Drain the coolant. Refer to Cooling System Draining and Filling .
5. Remove the reservoir mounting bolts.

6. Disconnect the coolant hose.
7. Remove the coolant recovery reservoir.
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Page 2 of 2
1. Connect the coolant hose to the coolant recovery reservoir.

2. Install the coolant recovery reservoir.
3. Install the mounting bolts.
Tighten
Tighten the recovery reservoir mounting bolts to 13 Nm (10 lb ft).
4.
5.
6.
7.
Install the battery.

Connect the positive battery cable.
Refill the cooling system. Refer to Cooling System Draining and Filling .
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Document ID: 218461
Page 1 of 3
Radiator Inlet Hose Replacement

Removal Procedure
Tools Required
J 37097-A Hose Clamp Remover/Installer
2. Drain the coolant. Refer to Cooling System Draining and Filling .
3. Remove the inlet radiator hose clamp from the radiator.

4. Remove the inlet raditor hose from the radiator.
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Page 2 of 3
5. Remove the inlet radiator hose clamp from the engine.

6. Remove the inlet radiator hose from the engine.
Tools Required
1. Install the inlet radiator hose to the engine.

2. Install the inlet radiator hose clamp to the engine.
2/7/2011
Document ID: 218461
3.
4.
5.
6.
Page 3 of 3
Install the inlet radiator hose to the radiator.

Install the inlet raditor hose clamp to the radiator.
Fill the cooling system. Refer to Cooling System Draining and Filling .
Start the engine and checks for leaks.
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Document ID: 218472
Page 1 of 3
Radiator Outlet Hose Replacement

Removal Procedure
Tools Required
3. Remove the outlet radiator hose clamp from the engine.

4. Remove the outlet radiator hose from the engine.
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Page 2 of 3
5. Remove the outlet radiator hose clamp from the radiator.

6. Remove the outlet radiator hose from the radiator.
Tools Required
1. Install the outlet radiator hose to the radiator.

2. Install the outlet radiator hose clamp to the radiator.
2/7/2011
Document ID: 218472
3.
4.
5.
6.
Page 3 of 3
Install the outlet radiator hose to the engine.

Install the outlet radiator hose clamp to the engine.
Fill the cooling system. Refer to Cooling System Draining and Filling .
Start the engine and checks for leaks.
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Document ID: 216001
Page 1 of 4
Engine Coolant Fan Replacement

Removal Procedure
Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan
blade or housing should always be replaced.
Caution: An electric fan under the hood can start up even when the engine is not running and can
injure you. Keep hands, clothing and tools away from any underhood electric fan.
2. Disconnect the electrical connector from the electric fan motor and fan bracket.
3. Remove the mounting bolts from the fan shroud.
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Document ID: 216001
Page 2 of 4
4. Remove the fan assembly from the radiator support.
5. Remove the fan blade from the electric fan motor.
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Page 3 of 4
1. Install the fan blade to the electric fan motor.
2. Install the fan assembly to the radiator support.
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Document ID: 216001
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3. Install the mounting bolts to the fan shroud.
Tighten
Tighten the mounting bolts to 10 Nm (89 lb in).
4. Connect the electrical connector to the electric fan motor and fan bracket.
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Document ID: 231197
Page 1 of 3
Engine Coolant Thermostat Replacement

Removal Procedure
2. Remove the engine cover.
3. Drain the cooling system. Refer to Cooling System Draining and Filling .
4. Disconnect the inlet radiator hose.
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Document ID: 231197
Page 2 of 3
5. Remove the thermostat housing.

6. Remove the thermostat (4).
7. Clean the gasket mating surfaces.
1. Install the thermostat (4).

2. Install the thermostat housing (2).
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Document ID: 231197
Page 3 of 3
3. Install the thermostat housing bolts (1).
Tighten
Tighten the thermostat housing bolts to 20 Nm (15 lb ft).
4.
5.
6.
7.
Install the inlet radiator hose.

Refill the cooling system. Refer to Cooling System Draining and Filling .
Install the engine cover.
Tighten
Tighten the negative battery cable bolt to 15 Nm (11 lb ft).
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Document ID: 215948
Page 1 of 3
Water Pump Replacement (VIN K)

Removal Procedure
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
4. Remove the water pump pulley bolts.

5. Remove the water pump pulley.
6. Clean the gasket mating surfaces.
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1. Using a new gasket, install the water pump on the engine.
2. Install the water pump bolts.
Tighten
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Document ID: 215948
Page 3 of 3
Tighten the bolts (1) to 15 Nm (11 lb ft).

3.
4.
5.
6.

Install the drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
Fill the coolant. Refer to Cooling System Draining and Filling .
Check for coolant leaks.
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Document ID: 215949
Page 1 of 3
Water Pump Replacement (VIN 1)

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Remove the bolts from the A/C compressor splash shield.
Remove the splash shield.
Drain the coolant. Refer to Cooling System Draining and Filling .
Remove the supercharger drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
Remove the coil pack. Position the coil pack out of the way.
Remove the supercharger belt tensioner. Refer to Drive Belt Tensioner Replacement in
Engine Mechincal.
Remove the engine mount. Refer to Engine Mount Replacement in Engine Mechincal.
Remove the power steering pump.
Remove the engine mount bracket.
Remove the idler pulley.
13. Remove the water pump pulley.
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Document ID: 215949
Page 2 of 3
14. Remove the water pump.

15. Clean all of the gasket mating surfaces.
1. Using a new gasket, install the water pump on the engine.

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Document ID: 215949
Page 3 of 3
2. Install the water pump bolts.
Tighten
3. Install the water pump pulley.

Tighten
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Install the idler pulley.

Install the engine mount bracket.
Install the power steering pump.
Install the engine mount. Refer to Engine Mount Replacement in Engine Mechincal.
Install the supercharger belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine
Mechincal.
Install the coil pack.
Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
Install the supercharger drive belt. Refer to Drive Belt Replacement in Engine Mechincal.
Refill the coolant. Refer to Cooling System Draining and Filling .
Install the A/C compressor splash shield.
Check for coolant leaks.
2/7/2011
Document ID: 215999
Page 1 of 2
Coolant Level Sensor Replacement

Removal Procedure
1. Remove the coolant level sensor electrical connector.

2. Remove the coolant level sensor.
1. Install the coolant level sensor.
2/7/2011
Document ID: 215999
Page 2 of 2
2. Install the coolant level sensor electrical connector.

3. Check the coolant level.
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Page 1 of 6
Radiator Replacement
Removal Procedure
2. Drain the engine coolant. Refer to Cooling System Draining and Filling .
3. Remove the upper fan mounting bolts.
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Document ID: 216024
Page 2 of 6
4. Remove the upper radiator panel.
5. Disconnect the radiator hoses from the radiator.

6. Disconnect the coolant recovery hose from the radiator neck.
7. Disconnect the electric cooling fan electric connector.
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Document ID: 216024
Page 3 of 6
8. Disconnect the transaxle oil cooler lines from the radiator side tank.
9. Remove the radiator from the vehicle.
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Document ID: 216024
Page 4 of 6
1. Install the radiator to the vehicle. Place the bottom of the radiator in the lower pads.
2. Connect the transaxle oil cooler lines to the radiator.

3. Tighten the transaxle oil cooler lines to the radiator.
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Document ID: 216024
Page 5 of 6
Tighten
Tighten the transaxle oil cooler line fittings to 27 Nm (20 lb ft).
4. Install the upper radiator panel.

Tighten
Tighten the upper radiator panel mounting bolts to 10 Nm (89 lb in).
5. Connect the radiator hoses to the radiator.
6. Connect the coolant recovery hose to the radiator neck.
7. Install the cooling fan assembly and the fan attaching bolts.
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Page 6 of 6
Tighten
Tighten the cooling fan bolts to 10 Nm (89 lb in).
8.
9.
10.
11.
Connect the fan connector.

Refill the engine coolant. Refer to Cooling System Draining and Filling .
Check for leaks.
2/7/2011
Document ID: 218507
Page 1 of 3
Coolant Heater Replacement

Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling .
2. Remove the transaxle brace to the engine assembly. Refer to Transmission Brace
Replacement .
3. Remove the cord from the engine coolant heater.
4. Loosen the bolt at theengine

coolant
heater
but do All
not
remove.
2011 General
Motors
Corporation.
rights
reserved.
2/7/2011
Document ID: 218507
Page 2 of 3
5. Remove the engine coolant heater.

6. Remove and clean any burrs, compound, paint, or rough spots from the core plug hole.
1. Apply a coat of Permatex Thread Sealant with Teflon to the O-ring and clean the surface of
the plug opening.
2. Install the coolant heater by pushing tight to the block.
3. Install the coolant heater so the element is positioned as shown.
2/7/2011
Document ID: 218507
Page 3 of 3
4. Tighten the bolt until both locking wings draw tight against the inner wall of the engine block.
Tighten
Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving
parts. Route the cord to the left front of the engine compartment securing with tie straps as
necessary to prevent damage.
5. Install the heater cord to the engine coolant heater.
6. Fill the engine cooling system. Refer to Cooling System Draining and Filling .
2/7/2011
Document ID: 219260
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre, LSS (VIN C/H) Service Manual | Engine | Engine Exhaust |

Specification
Application
Metric
English
Front Exhaust Pipe-to-Manifold Bolt (L36 & L67)
25 Nm
18 lb ft
U-Bolt Clamp Nuts
40 Nm
30 lb ft
tomsn048@gmail.com
2/7/2011
Document ID: 219278
Page 1 of 1
Exhaust System Clearances

Specification
Application
Metric English
Front Exhaust Pipe to the Front Stabilizer Bar
37 mm 1.45 in
Heatshield to the Converter
31 mm 1.22 in
Intermediate Pipe/Resonator and the Splash Shield to the Fuel Tank facing
the RH of the vehicle
37 mm 1.45 in
Intermediate Pipe/Resonator and the Splash Shield at 55 degrees to the

heat shield toward facing to the rear of the vehicle
48 mm 1.89 in

heat shield toward facing to the rear of the vehicle
24 mm 0.94 in

heat shield facing to the front of the vehicle
43 mm 1.69 in

heat shield facing to the front of the vehicle
29 mm 1.14 in
Intermediate Pipe/Resonator and the Splash Shield at 45 degrees to RH of

the of the Rear Stabilizer Bar
23 mm 0.90 in
Tailpipe to the Muffler
13 mm
0.5 in
Tailpipe to the Rear Fascia (Pontiac)
49 mm
1.9 in
Tailpipe to the Rear Fascia (Oldsmobile Eighty-Eight)
24 mm 0.94 in
Tailpipe to the Rear Fascia (Buick LeSabre)
29 mm 1.14 in
tomsn048@gmail.com
2/7/2011
Document ID: 219830
Page 1 of 2
Exhaust System Alignment

1. The exhaust system hangers minimize noise transfer. Vibration and noise can be transmitted
into the vehicle under the following conditions:
System contact with the body
A restricted hanger
2. Position the clamps and the insulator so that the hanger is vertical, when the exhaust system
is at operating temperature.
3. Inspect that the brackets are horizontal.
Important: Allow the pipes to cool before touching them.
4. Use heat in front of the rear suspension, in order to reposition the pipes if necessary.
5. Do not use an acetylene torch near the fuel tank.
tomsn048@gmail.com
2/7/2011
Document ID: 219830
Page 2 of 2
6. Inspect that the support brackets are horizontal.

7. Inspect that the clearance between the frame members and the floor pan is a minimum of
15 mm (5/8 in) after the following procedures:
Hanger adjustment
Pipe positioning
8. Tighten all clamps according to the specified torques. Refer to Fastener Tightening
Specifications .
9. Clearance is needed in order to avoid the following conditions:
Overheating of the floor pan
Damage to the passenger compartment carpets
10. Inspect that the weight of the system is evenly distributed according to the equal deflection
at each hanger on the following components:
The brackets
The hangers
11. Ensure that the exhaust system has the proper clearances. Refer to Exhaust System
Clearances .
tomsn048@gmail.com
2/7/2011
Document ID: 219831
Page 1 of 4
Intermediate Pipe Replacement

Tools Required
J 29800 Cut-Off Tool
Removal Procedure
A service muffler is required when replacing the intermediate pipe/resonator on an originally
equipped welded system.
Important: The NEW intermediate pipe/resonator will slide over the remaining portion of the
intermediate pipe/resonator.
1. Cut (1) near the edge of the expanded portion of the intermediate pipe/resonator (2) using
the J 29800 .
tomsn048@gmail.com
2/7/2011
Document ID: 219831
Page 2 of 4
2. Remove the hangers from the intermediate pipe/resonator.

3. Support the following:
The intermediate pipe/resonator
The catalytic converter
4. Remove the hanger bolts from the tail pipes.

5. With the aid of an assistant, lower the intermediate pipe/resonator and muffler assembly
from the vehicle.
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Document ID: 219831
Page 3 of 4
1. Loosely install the muffler with a U bolt type clamp to the intermediate pipe/resonator.
2. With the aid of an assistant, raise the intermediate pipe/resonator and muffler assembly into
position under the vehicle.
3. Install the hanger bolts to the tail pipes.
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Document ID: 219831
Page 4 of 4
Tighten
Tighten the rear exhaust hanger bolts to 20 Nm (15 lb ft).
4. Slide the intermediate pipe/resonator over the catalytic converter outlet.

5. Loosely install a U bolt type clamp to the intermediate pipe/resonator.
6. Install the hangers to the intermediate pipe/resonator.

7. Align the system for proper clearances to the underbody. Refer to Exhaust System
Alignment .
8. Tighten the U bolt type clamps previously installed in steps 1 and 5.
Tighten
Tighten the U bolt clamp nuts to 40 Nm (30 lb ft).
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2/7/2011
Document ID: 219262
Page 1 of 6
Catalytic Converter Replacement

Tools Required
J 29800 Cut-Off Tool
Removal Procedure
1. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.
Important: Ensure a minimum of 38 mm (1.5 inches) of the expanded portion of the

intermediate pipe/resonator remains for installation.
2. Cut the intermediate pipe/resonator (1) at the converter weld using the J 29800 . Cut the
pipe as close to the weld as possible.
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Document ID: 219262
Page 2 of 6
3. Remove the hangers from the intermediate pipe/resonator.

4. Support the following:
5. Separate the intermediate pipe/resonator from the catalytic converter.
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Document ID: 219262
Page 3 of 6
6. If both pipes were cut through in step 2, remove the remainder of the catalytic converter
pipe from the intermediate pipe/resonator.
7. Remove the 4 nuts securing the catalytic converter to the exhaust manifold pipe.
8. Remove the catalytic converter from the exhaust manifold pipe.
9. Remove the catalytic converter gasket. Do not reuse the gasket.
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Document ID: 219262
Page 4 of 6
1. Place a NEW catalytic converter gasket over the catalytic converter studs.
2. Position the catalytic converter to the exhaust manifold pipe.
3. Install the 4 nuts securing the catalytic converter to the exhaust manifold pipe.
Tighten
Tighten the catalytic converter nuts to 25 Nm (18 lb ft).
4. Support the catalytic converter.
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2/7/2011
Document ID: 219262
Page 5 of 6
5. Slide the intermediate pipe/resonator over the catalytic converter outlet.

6. Align the system for proper clearances to the underbody. Refer to Exhaust System
Alignment .
7. Install the U bolt type clamp.
Tighten
Tighten the U bolt clamp nuts to 40 Nm (30 lb ft).
8. Install the hangers to the intermediate pipe/resonator.

9. Remove the supports from the following:
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2/7/2011
Document ID: 219262
Page 6 of 6
10. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.
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2/7/2011
Document ID: 219265
Page 1 of 2
Exhaust Muffler Replacement

Removal Procedure
1. Support the intermediate pipe/resonator assembly.

2. Cut the intermediate pipe/resonator.
3. Remove the muffler hangers.

4. Remove the muffler.
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2/7/2011
Document ID: 219265
Page 2 of 2
1.
2.
3.
4.
Install the muffler.

Install the muffler hangers.
Install the intermediate pipe/resonator assebly to the muffler.
Align the muffler and the intermediate pipe/resonator to the proper clearance. Refer to
Exhaust System Alignment .
5. Install the U bolt type clamp.

Tighten
Tighten the clamp nuts to 40 Nm (30 lb ft).
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2/7/2011
Document ID: 219266
Page 1 of 2
Converter Heat Shield Replacement

Removal Procedure
1. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls.
Notice: The Heated Oxygen Sensor (HO2S) uses a permanently attached pigtail and
connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the
removal of the pigtail or the connector could affect the proper operation of the sensor.
2. Remove the heat shield retaining bolts.

3. Remove the oxygen sensor connector from the shield.
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2/7/2011
Document ID: 219266
Page 2 of 2
1. Install the oxygen sensor connector on the shield.

2. Install the heat shield retaining bolts on the vehicle.
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2/7/2011
Document ID: 299663
Page 1 of 1
Entertainment | Specifications | Document ID: 299663

Specification
Application
Metric
English
5 Nm
44 lb in
Antenna Module Fastener
7.5 Nm
66 lb in
Antenna to Bracket Fastener
7.5 Nm
66 lb in
BOSE Amplifier Fasteners
2 Nm
18 lb in
Extended Range Rear Package Shelf Speaker Fasteners
1.9 Nm
17 lb in
Fixed Antenna Ground Lead Fastener
7.5 Nm
66 lb in
Front Door Speaker Fasteners
1.4 Nm
17 lb in
Front Door Tweeter Speaker Fasteners
1.4 Nm
12 lb in
Front Extended Range IP Speaker Fasteners
1.9 Nm
12 lb in
4 Nm
35 lb in
1.9 Nm
17 lb in
Antenna Mast
Power Antenna Ground Lead Fastener

Radio Fasteners
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2/7/2011
Document ID: 344121
Page 1 of 1
Entertainment | Schematic and Routing Diagrams | Document ID: 344121
Cell 150: Radio Power and Ground (Buick)
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2/7/2011
Document ID: 344133
Page 1 of 1
Cell 150: RH Speakers (Buick w/UW6)
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2/7/2011
Document ID: 344145
Page 1 of 1
Cell 150: LH Speakers (Buick w/UW6)
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Document ID: 344125
Page 1 of 1
Cell 150: Speakers (Buick w/UQ8)
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Document ID: 346380
Page 1 of 1
Steering Wheel Controls Schematics

Cell 152
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Document ID: 344166
Page 1 of 1
Cell 151: Power Antenna
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Document ID: 344163
Page 1 of 1
Cell 151: Rear Window Antenna
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Document ID: 343343
Page 1 of 1
Entertainment | Component Locator | Document ID: 343343
Passenger Compartment, Steering Column
(1) C202
(2) Ignition Switch
(3) Shift Interlock Actuator (Hidden)
(4) Horn Switch
(5) Inflatable Restraint Steering Wheel Module
(6) Steering Wheel Controls LH and RH
(7) Inflatable Restraint Steering Wheel Module Coil
(8) Headlamp Dimmer Switch
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Document ID: 343355
Page 1 of 1
Instrument Panel, Under the Center
(1) Audio Amplifier (BOSE)
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Document ID: 343436
Page 1 of 1
Right Front Door, Behind the Door Trim
(1) RH Front Door Speaker Connector (LH Similar)

(2) C602
(3) S601
(4) C216
(5) C209
(6) S600
(7) S603
(8) P600
(9) RH Front Door Speaker (LH Similar)
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2/7/2011
Document ID: 400526
Page 1 of 1
Passenger Compartment, Pontiac Instrument Panel Shown,

Others Similar
(1) Instrument Cluster

(2) Cigar Lighter
(3) Heater and A/C Control
(4) Inflatable Restraint IP Module
(5) Radio
(7) Fog Lamp Switch
(8) Lamp Dimmer Switch
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2/7/2011
Document ID: 400546
Page 1 of 1
Passenger Compartment, Rear Package Shelf Area
(1) RH Rear Strut Tower -- LH Similar

(2) RH Rear Strut Actuator -- LH Similar (Pontiac w/FW1)
(3) RH Rear Speaker
(4) LH Rear Speaker
(5) P408
(6) S301
(7) P400
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Document ID: 343445
Page 1 of 1
Right Hand of the Rear Compartment
(1) Power Antenna Relay

(2) Power Antenna
(3) Antenna Coaxial Cable
(4) Power Antenna Mast Ground
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2/7/2011
Document ID: 359518
Page 1 of 11
Entertainment Connector End Views

Table 1:
Audio Amplifier (w/ UZ8)
Table 2:
Radio (Oldsmobile/Buick)
Table 3:
Radio C1 (Pontiac)
Table 4:
Radio C2 (Pontiac)
Table 5:
Radio C3 (Pontiac)
Table 6:
RH Front Door Speaker (Oldsmobile/Pontiac)
Table 7:
RH Front Door Speaker (Buick)
Table 8:
RH IP Speaker (UQ8)
Table 9:
RH Rear Speaker (Tweeter)
Table 10: RH Rear Speaker (Woofer)

Table 11: RH Rear Speaker (Buick)
Table 12: LH Front Door Speaker (Pontiac/Oldsmobile)
Table 13: LH Front Door Speaker (Buick)
Table 14: LH IP Speaker (UQ8)
Table 15: LH Rear Speaker (Woofer)
Table 16: LH Rear Speaker (Buick)
Table 17: LH Rear Speaker
Table 18: LH Rear Speaker
Audio Amplifier (w/ UZ8)
12110088
24 Way F Micro-Pack 100 Series (GRY)
Pin
Wire Color
Circuit No.
A1
BRN
199
Speaker Feed-Left Rear
A2
YEL
116
Speaker Return - Left Rear
A3
--
--
A4
DK GRN
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1947
Function
Not Used
Audio Signal - Left Front
2/7/2011
Document ID: 359518
Page 2 of 11
A5
BRN
1999
Audio Signal - Left Rear
A6
LT GRN
1948
Audio Signal - Right Front
A7
BLK
1946
Audio Signal - Right Rear
A8
ORN
360
A9-A10
--
--
A11
DK GRN
117
A12
ORN
40
B1
BLK
1250
B2
TAN
201
Speaker Feed - Left Front
B3
GRY
118
Speaker Return - Left Front
B4
--
--
B5
TAN
511
Audio Input - Left Front
B6
BRN
599
Audio Input - Left Rear
B7
LT GRN
512
Audio Input - Right Front
B8
DK BLU
546
Speaker Return - Right Rear
B9
--
--
B10
LT BLU
115
B11
DK BLU
46
Speaker Feed - Right Rear
B12
LT GRN
200
Speaker Feed - Right Front
Switch Battery Power

Not Used
Speaker Return - Right Front
Fused Output-Battery
Ground
Not Used
Not Used
Radio (Oldsmobile/Buick)
Connector Part
Information
12110115
32 Way F Micro-Pack 100 Series (BLU)
Pin
Wire Color
Circuit
No.
E1
DK GRN
835
E2- E3
--
--
E4
PPL/WHT
724
E5
LT GRN
1011
Function
Diagnostic Signal - E & C
Not Used
Vacuum Fluorescent Dimming Signal
Remote Radio Control Signal
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Document ID: 359518
Page 3 of 11
Remote Control Signal (Buick with C67/U23 or

UB3)
E6
LT GRN
1011
E7-E11
--
--
E12
BRN
199
Left Rear Speaker Feed
E13
YEL
116
Left Rear Speaker Return
E14
DK GRN
117
Right Front Speaker Return
E15
LT GRN
200
Right Front Speaker Feed
E16
BLK
1250
F1
ORN
40
F2
YEL
43
Fused Output - Accessory
F3
DK GRN
145
F4
GRY
F5
YEL
32
Fused Output - Instrument Panel Lamps
F6-F7
--
--
Not Used
F8
BLK
1250
F9-F11
--
--
F12
TAN
201
Left Front Speaker Feed
F13
GRY
118
Left Front Speaker Return
F14
LT BLU
115
Right Rear Speaker Return
F15
DK BLU
46
Right Rear Speaker Feed
F16
--
--
Not Used
Not Used
Ground
Power Antenna Relay Feed Coil

Ground (Buick)
Not Used
Radio C1 (Pontiac)
12047531
F Micro - Pack 100 Series (BLK)
Pin
Wire Color
Circuit No.
Function
GRY
118
Left Front Speaker Return
TAN
201
Left Front Speaker Feed
DK GRN
117
Right Front Speaker Return
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Right Front Speaker Feed
LT GRN
200
BLK
1250
YEL
32
GRY
DK GRN
145
YEL
43
Fused Output - Accessory
10
ORN
40
Ground
Fused Output - Instrument Panel Lamps
instrument Panel Lamps Feed
Power Antenna Relay Feed - Coil
Radio C2 (Pontiac)
12065785
10-Way F Micro - Pack 100 Series (GRY)
Pin
Wire Color
Circuit No.
Function
11
BLK
1250
12-13
--
--
14
LT GRN
1011
15
DK GRN
835
16
--
--
17
LT BLU
115
18
DK BLU
46
Right Rear Speaker Feed
19
YEL
116
Left Rear Speaker Return
20
BRN
199
Left Rear Speaker Feed
Ground (with UZ8)

Not Used
Remote Radio Control Signal
Diagnostic Signal - E&C
Not Used
Right Rear Speaker Return
Radio C3 (Pontiac)
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Document ID: 359518
Page 5 of 11
12064980
9 Way F Micro-Pack 100 Series (BLK)
Pin
Wire Color
Circuit No.
ORN
360
8-15
--
--
Function
Amplifier Feed
Not Used
RH Front Door Speaker (Oldsmobile/Pontiac)
12052832
Pin
Wire Color
Circuit No.
Function
DK GRN
117
Speaker Return -Right Front
LT GRN
200
Speaker Feed -Right Front
RH Front Door Speaker (Buick)
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Document ID: 359518
Page 6 of 11
12064760
4 Way F Metri-Pack 150 Series
Pin
Wire Color
Circuit No.
LT GRN
200
LT GRN
200
DK GRN
117
DK GRN
117
Function
RH IP Speaker (UQ8)
12052832
2-Way Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit No.
Function
DK GRN
117
LT GRN
200
RH Rear Speaker (Tweeter)
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Document ID: 359518
Page 7 of 11
12052832
2 Way F Metric-Pack Series 150 (BLK)
Pin
Wire Color
Circuit No.
LT BLU
115
DK BLU
46
Function
RH Rear Speaker (Woofer)
12064760
2 Way F Metric-Pack 150 Series (BLK)
Pin
Wire Color
Circuit No.
Function
LT BLU
115
DK BLU
46
C-D
--
--
Not Used
RH Rear Speaker (Buick)
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Document ID: 359518
Page 8 of 11
12047662
2-Way F Metri-Pack Series 150 (BLK)
Pin
Wire Color
Circuit No.
LT BLU
115
DK BLU
46
Function
LH Front Door Speaker (Pontiac/Oldsmobile)
12052832
2 Way F Metri-Pak 150 Series (BLK)
Pin
Wire Color
Circuit No.
Function
GRA
118
Speaker Return - Left Front
TAN
201
Speaker Feed - Left Front
LH Front Door Speaker (Buick)
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Document ID: 359518
Page 9 of 11
12064760
Pin
Wire Color
Circuit No.
TAN
201
Speaker Feed Left Front
TAN
201
GRA
118
Speaker Return Left Front
GRA
118
Function
LH IP Speaker (UQ8)
12052832
Pin
Wire Color
Circuit No.
Function
GRA
118
TAN
201
LH Rear Speaker (Woofer)
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Document ID: 359518
Page 10 of 11
12064760
Pin
Wire Color
Circuit No.
YEL
116
Speaker Return Left Rear
BRN
199
Speaker Feed Left Rear
C-D
--
--
Function
Not Used
LH Rear Speaker (Buick)
12047662
Pin
Wire Color
Circuit No.
Function
YEL
116
BRN
199
LH Rear Speaker
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Document ID: 359518
Page 11 of 11
12052832
Pin
Wire Color
Circuit No.
YEL
116
BRN
199
Function
LH Rear Speaker
12064760
Pin
Wire Color
Circuit No.
Function
YEL
116
BRN
199
C-D
--
--
Not Used
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2/7/2011
Document ID: 413414
Page 1 of 2
Entertainment | Repair Instructions | Document ID: 413414
Radio Replacement (Buick)

Removal Procedure
1. Remove the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement in
Instrument Panel, Gauges and Console.
2.
3.
4.
5.
6.
Remove the fasteners that secure the radio.

Pull rearward the radio.
Disconnect the electrical connector(s).
Disconnect the antenna lead.
If you replace the radio, remove the mounting bracket from the radio.
1. If the radio was replaced, install the old mounting bracket.
2. Connect the antenna lead.
3. Connect the electrical connector(s).
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Document ID: 413414
Page 2 of 2
4. Install the radio.

5. Install the radio fasteners.
Tighten
6. Install the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement in
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2/7/2011
Document ID: 415141
Page 1 of 2
Cassette Player Care and Cleaning

Tools Required
J 39916-A Audio System Diagnostic Kit
If you do not regularly clean the tape player, the tape player is subject to the following conditions:
Reduced sound quality
Ruined cassettes
A damaged tape mechanism
Cassette tapes may not operate properly if they are not stored in their cases away from the
following conditions:
Contaminants
Direct sunlight
Extreme heat
Cleaning Intervals
Clean the cassette tape player every 15 hours of operation for optimum performance.
Clean the cassette tape player at a maximum of every 50 hours of playing time. This will prevent
damage to the cassette tape player mechanism. The radio may display CLN, CLEAN or CLEAN TAPE
(depending on the family of radio being used), if equipped with the Clean Tape Indicator Feature.
This indicates that you have used the tape player for 50 hours without resetting the tape clean
timer. If this message appears on the display, clean the cassette tape player. The player will still
play tapes, however the player should be cleaned as soon as possible in order to prevent damage
to the tapes and/or the player.
Cassettes are subject to wear and the sound quality may degrade over time. If you notice a
reduction in sound quality, play a different cassette. A new cassette will indicate whether the tape
or the tape player is at fault.
If the sound quality does not improve when the second tape is played, clean the cassette player.
Perform this step regardless of when you last cleaned the cassette player.
If a noticeable improvement is not achieved after cleaning the player, remove the radio assembly
for repair.
Head and Capstan Cleaning

The following two components are cleaned on a tape player:
The head
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Document ID: 415141
Page 2 of 2
The capstan
Important: Do not contact the tape head with magnetized tools. If the head becomes magnetized,
every cassette played in the player will be degraded.
In order to properly clean a tape player, the preferred method would be to use the cleaning
cassette in J 39916-A in order to clean the head and the capstan. The cleaning cassette is a
scrubbing action, non abrasive cassette with pads which scrub the tape head as the hubs of the
cleaner cassette turn. When using a scrubbing action, non abrasive cleaning cassette, it is normal
for the cassette to eject. The unit is equipped with a cut tape detection feature and the cleaning
cassette may appear as a broken tape.
To prevent the cleaning cassette from being ejected, perform the following steps:
1. Turn the ignition switch to one of the following positions (depending on the vehicle line):
ON
RUN
ACC
2.
3.
4.
5.
ACCESSORY
Turn the radio off.
Press and hold the TAPE button for five seconds. The tape symbol on the display will flash for
two seconds.
Insert the scrubbing action cleaning cassette.
Eject the cleaning cassette after the manufacturer's recommended cleaning time. When the
cleaning cassette has been ejected, the Cut Tape Detection Feature is active again.
The alternative method would be to use a non scrubbing action, wet type cleaning cassette. This
cassette uses a fabric belt to clean the tape head. This type of cleaning cassette will not eject on its
own. A non scrubbing action cassette may not clean as thoroughly as the scrubbing type cleaning
cassette. The use of this cassette is not recommended.
After you clean the player, press and hold the EJECT button for five seconds to reset the CLEAN
indicator. The radio will display --- to show that the indicator has been reset.
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2/7/2011
Document ID: 383568
Page 1 of 2
Fixed Antenna Mast Replacement

Removal Procedure
Notice: Use tape on the tool surface so that you do not damage the paint on the antenna
mast.
1. Unscrew the antenna mast.
2. Remove the antenna mast from the antenna base.
Notice: Use tape on the tool surface so that you do not damage the paint on the antenna
mast.
1. Install the antenna mast to the antenna base.
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Document ID: 383568
Page 2 of 2
2. Secure the antenna mast to the antenna base.
Tighten
Tighten the antenna mast to 5.5 Nm (49 lb in).
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2/7/2011
Document ID: 492037
Page 1 of 2
Radio Antenna Replacement

Removal Procedure
1. Remove the rear compartment trim. Refer to Rear Compartment Side Trim Replacement Right Side in Body Rear End.
2. Remove the antenna mast. Refer to Fixed Antenna Mast Replacement .
3.
4.
5.
6.
7.
Disconnect the coaxial lead (4) from the antenna assembly (3).
Remove the antenna ground lead bolt (7).
Remove the antenna bracket bolt (6).
Remove the antenna assembly (3).
Remove the bezel (2) from the quarter panel.
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Document ID: 492037
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1. Apply a lubricant to the bezel (2).

2. Install the bezel to the quarter panel.
3. Install the antenna assembly (3).
4. Install the antenna bracket bolt (6).
Tighten
5. Install the antenna ground lead bolt (7).
Tighten
6. Connect the coaxial lead (4) to the antenna assembly.
7. Install the antenna mast. Refer to Fixed Antenna Mast Replacement .
8. Install the rear compartment trim. Refer to Rear Compartment Side Trim Replacement Right Side in Body Rear End.
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2/7/2011
Document ID: 404121
Page 1 of 2
Radio Antenna Module Replacement

Removal Procedure
Important: The antenna is located in the rear window. For window replacement, refer to
Rear Window Replacement in Stationary Windows.
1. Remove the right sail panel trim (1). Refer to Rear Quarter Trim Panel Replacement in
Interior Trim.
2. Remove the body harness (5).
Remove the antenna coaxial cable (4) from the antenna module (2).
3. Remove the bolt (3).
4. Disengage the tab on the module (2) from the slot in the sail panel (1).
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Document ID: 404121
Page 2 of 2
1. Engage the module tab in the slot in the sail panel (1).
2. Rotate the module down in order to align the hole for the bolt (3).
3. Install the fastener (3).
Tighten
4. Insert the body harness (5).
5. Insert the antenna coaxial cable (4) to the antenna module (2).
6. Install the right sail panel trim (1). Refer to Rear Quarter Trim Panel Replacement in Interior
Trim.
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2/7/2011
Document ID: 299667
Page 1 of 3
Power Antenna Mast Replacement

Removal Procedure
1. Position the antenna mast (2).

If the antenna mast is completely down, perform the following steps:
1. With the ignition key in ACCY position, ask a helper to turn the radio to the ON
position.
2. When the mast tip (1) extends approximately 25.4 mm (1 in), remove the power by
pulling the fuse.
If the antenna mast is above the fender, remove power by pulling the fuse.
2. Remove the insulator stop (5), using a 14 mm deep well 12 point socket.
3. Use a wrench or a suitable tool on the flat portions of the mast tip in order to remove the
mast tip (1).
Grip the rod assembly (2) with pliers which are padded with cloth or rubber. This will
prevent the rod assembly from turning.
Do not bend the rod (2).
4. Slide over the rod assembly using long nose pliers or your fingers.
5. Remove the inner tube assembly (3).
6. Remove the outer tube assembly (4).
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Document ID: 299667
Page 2 of 3
1. Lubricate the contractor (5) with supplied lubricant before you assembly a new mast.
2. Slide the assembly tool (4) over the contractor (5) in order to compress the fingers. The
assembly tool is included in the replacement parts package.
3. Slide the mast assembly over the rod assembly (2) and into the stationary tube (9) past the
contractor fingers.
4. Remove the assembly tool.
5. Install the bottom mast into the stationary tube (9).
The threaded top of the rod assembly (2) must be above the top of the inner rod
assembly (3).
6. Install the insulator stop (5).
7. Install the mast tip (1).
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Document ID: 299667
Page 3 of 3
8. Return the fuse.
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Document ID: 299668
Page 1 of 2
Power Antenna Assembly Replacement

Removal Procedure
1. Pull back the rear compartment trim. Refer to Rear Compartment Side Trim Replacement Right Side in Body Rear End.
2. Remove the antenna ground lead bolt (3).
3. Remove the drain hose (6) from the drain hole.
4. Remove the antenna bracket bolt (5).
Make note of fastener position before removal.
5.
6.
7.
8.
9.
Partially remove the antenna assembly (2).

Disconnect the coaxial lead (7).
Disconnect the relay connector (4).
Remove the antenna assembly.
Remove the bezel (1) from the quarter panel.
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Document ID: 299668
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Important: Do not use a petroleum based lubricant.

1.
2.
3.
4.
5.
6.
Apply lubricant to the bezel (1).

Install the bezel to the rear quarter panel.
Partially install the antenna assembly (2).
Connect the relay connector (4).
Connect the coaxial lead (7) to the antenna.
Insert antenna tip into antenna bezel to seat.
Hold antenna bezel from the top to keep it from popping out.
7. Install the antenna bracket bolt (5).

Tighten
Tighten the antenna bracket bolt to 7.5 Nm (66 lb in).
8. Install the drain hose (6) through the drain hole.
9. Install the antenna ground lead bolt (3).
Tighten
Tighten the antenna ground lead bolt to 4 Nm (35 lb in).
10. Install the rear compartment trim. Refer to Rear Compartment Side Trim Replacement Right Side in Body Rear End.
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Document ID: 383566
Page 1 of 1
Antenna Mast Cleaning

Important: Clean the antenna periodically in order to assure proper operation of the radio and the
power antenna.
1. Turn the ignition to one of the following positions, depending on the vehicle line:
ON
RUN
ACC
ACCESSORY
2. Turn the radio ON in order to raise the antenna mast to the full extension.
3. Dampen a soft cloth using a grease cleaning solvent such as one of the following materials:
Mineral spirits
Rubbing alcohol
Tar remover
4. Wipe the cloth over the mast sections, removing any dirt, particularly at the mast section
joints.
5. Turn the radio OFF and ON in order to retract and extend the antenna. Repeat Steps 2
through Step 4 at least 2 more times.
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2/7/2011
Document ID: 469325
Page 1 of 2
Radio Front Side Door Speaker Replacement

(Buick/Oldsmobile)
Removal Procedure
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement in Doors.
2. Note the location of the speaker electrical connector.

4. Remove the fasteners.
5. Remove the speaker.
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Document ID: 469325
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1. Install the speaker into the door with the electrical connector located as noted during
removal.
2. Install the speaker fasteners.
Tighten
4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement in Doors.
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2/7/2011
Document ID: 469343
Page 1 of 2
Radio Front Speaker Replacement (Buick with UQ8)

Removal Procedure
1. Remove the IP upper trim pad. Refer Instrument Panel Upper Trim Pad Replacement in
2. Remove the fasteners.
3. Raise the speaker (1).
4. Disconnect the electrical connector(s).
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Document ID: 469343
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1. Connect the electrical connector(s).

2. Install the speaker (1).
3. Install the speaker fasteners.
Tighten
4. Install the IP upper trim pad. Refer Instrument Panel Upper Trim Pad Replacement in
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2/7/2011
Document ID: 412214
Page 1 of 2
Radio Rear Speaker Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
Disconnect the electrical connector.

Remove the speaker bracket mounting fasteners.
Lower the speaker bracket.
Remove the speaker from the bracket (1).
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Document ID: 412214
1.
2.
3.
4.
Page 2 of 2
Install the speaker to the bracket (1).

Raise the speaker bracket up to rear shelf.
Install the speaker bracket mounting fasteners.
Connect the electrical connector.
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2/7/2011
Document ID: 510333
Page 1 of 1
Exterior Trim | Specifications | Document ID: 510333

Specification
Application
Metric
English
Front Fascia to Fender Nuts
2.8 Nm
25 lb in
Rear Fascia to Quarter Nuts
9.5 Nm
84 lb in
Wheel Opening Molding Screws - Buick
1.9 Nm
17 lb in
Wheel Opening Molding Screws - 88/LSS
2.1 Nm
18 lb in
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Document ID: 298680
Page 1 of 2
Exterior Trim | Repair Instructions | Document ID: 298680
Front Fender Body Side Molding Replacement (Buick)

Removal Procedure
1. Remove the front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front
End.
2. Remove the 2 nuts (2).

3. Remove the molding.
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Document ID: 298680
Page 2 of 2

The molding (3)
The 2 nuts (2
2. Install the front wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front
End.
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Document ID: 298691
Page 1 of 2
Front Fender Wheel Opening Molding Replacement

(Buick)
Removal Procedure
1. Remove the screws (1) that retain the wheel opening molding (2).
2. Remove the wheel opening molding (2).
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Document ID: 298691
Page 2 of 2
1. Install the wheel opening molding (2).

2. Install the screws (1) in order to retain the wheel opening molding (2).
Tighten
Tighten the screws (1) to 1.9 Nm (17 lb in).
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2/7/2011
Document ID: 298700
Page 1 of 2
Door Body Side Molding Replacement (Buick)

Removal Procedure
1. Remove the retaining screw.

2. Pull the molding (2) upward and gently pry the molding off along the top edge.
3. Slide the molding down off of the lower clips.
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Document ID: 298700
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1. Install the molding (2).

2. Install the retaining screw.
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Document ID: 298711
Page 1 of 2
Rear Side Door Molding Replacement

Removal Procedure
1. Remove the screws (2) that retain the molding to the door.
2. Remove the molding (1) from the door.
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Document ID: 298711
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1. Install the molding (1) to the door.

2. Install the retaining screws (2).
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Document ID: 298715
Page 1 of 2
Rear Quarter Molding Replacement

Removal Procedure
1. Remove the nuts (2) that retain the molding to the rear quarter.
2. Remove the molding (1) from the rear quarter.
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Document ID: 298715
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1. Install the molding (1) to the rear quarter.

2. Install the retaining nuts (2).
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Document ID: 298723
Page 1 of 2
Rear Wheel Opening Molding Replacement

Removal Procedure
1. Remove the screws (1) that retain the wheel opening molding (2).
2. Remove the wheel opening molding (2).
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Document ID: 298723
1.
2.
3.
4.
Page 2 of 2
Align the wheel opening molding (2) with the feature line on the body.
Install the top center screw (1) in order to hold the molding (2) in position.
Install the screws (1) to the center of the molding (2) rearward.
Install the screws (1) to the center of the molding (2) forward.
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2/7/2011
Document ID: 298729
Page 1 of 2
Rocker Panel Molding Replacement (Buick)

Removal Procedure
1. Remove the screws (2).

2. Slide the molding (1) toward the rear of the vehicle in order to disengage the fasteners, if
equipped.
3. Remove the rocker panel molding (1).
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Document ID: 298729
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1. Position the rocker panel molding (1).

2. Secure the molding (1) by striking firmly at each clip location, if equipped.
3. Install the screws (2).
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2/7/2011
Document ID: 510027
Page 1 of 1
Weld Stud Replacement

If a weld stud becomes damaged during a repair procedure, use the following procedure in order to
replace the weld stud:
1. Drill a hole into the same location as the damaged weld stud.
2. Drive a new screw into the drilled hole.
3. Use a screw in order to retain the clips, molding, etc. in the same manner used with the weld
studs.
4. If the surface becomes marred, repair and/or paint the surface in order to provide a smooth
surface. Refer to Clearcoat Repair without Repainting in Paint/Coatings.
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2/7/2011
Document ID: 298744
Page 1 of 1
Molding Clip Replacement

Use the following procedure if a weld stud on an outer panel becomes damaged or broken off:
1. Drill a small hole in the panel next to the original weld stud location.
2. Complete one of the following steps:
Insert a self-sealing screw through the original clip and into the outer panel.
Replace the damaged weld stud with a self-sealing, screw-type weld stud.
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2/7/2011
Document ID: 298747
Page 1 of 2
Grille Replacement (LeSabre)

Removal Procedure
1. Open the hood (1).

2. Remove the nuts (2) that retain the grille (3) to the hood (1).
3. Remove the grille (3).
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Document ID: 298747
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1. Install the grille (3).

2. Install the nuts (2) in order to retain the grille (3) to the hood (1).
Tighten
Tighten the nuts (2) to 5 Nm (44 lb in).
3. Close the hood (1).
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Document ID: 511321
Page 1 of 2
Decal or Stripe Replacement

Stripe and Decal Application
Apply decals in a clean environment where dust and fibers will not interfere with proper adhesion.
Perform the following steps in order to apply the decals:
1. Clean the area where you will mount the decal.
Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and
50 percent water.
2.
3.
4.
5.
6.
Dry the area thoroughly.

If there is a chip in the paint area, refinish the area and feather the area in.
Warm the body surface and the decal to 27-38C (80-100F).
You can apply most stripes and decals dry as long as this results in a bubble-free application.
Use the Wet Method when the following apply:
When the stripe or decal wraps into the body openings.
When you mount the stripe or decal on a flexible surface.
Wet Method
1. Use a wetting agent such as Dupont Duponal WA or equivalent.
Do not use a soap solution.
Spray a mist of the solution onto the body area.
2. Remove the backing from the decal by peeling the backing away.
In hot, humid weather, spray the adhesive back of the decal with a mist of the wetting
solution.
3. Using a squeegee, start at the center of the decal and squeegee the decal onto the body.
This removes any air bubbles and the wetting solution.
4. Remove the premask from the decal by pulling the premask back.
Do not lift the premask straight up.
5. Go over the decal again with the squeegee.
6. If air bubbles are still present, prick the air bubbles with a pin.
Use the squeegee in order to remove air from the bubble.
Adhesive Retained Items

1. Clean the area where you will mount the replacement item.
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Document ID: 511321
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Use a suitable solvent such as flash naphtha or a mixture of 50 percent isopropyl alcohol and
50 percent water.
2. Dry the area thoroughly with a clean cloth.
3. If there is a chip in the paint in the area, refinish the area and feather the area in.
4. The body area, and the temperature of the item to be applied, must be at a temperature of
27C (80F) or 6C (10F) above the air temperature in the application area, whichever is
higher.
Do not install adhesive backed items at temperatures above 41C (105F).
You may use infrared heat in order to warm the body panels to the specified temperature.
5. Remove the backing by peeling the backing away from the item.
6. Mount the item. Apply 155 Nm (35 lb) of even pressure for three seconds to the item in
order to wet out at least 75 percent of the adhesive.
7. If an emblem or name plate has a premask, remove the premask by pulling the premask
back.
Do not lift the premask straight up.
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2/7/2011
Document ID: 359965
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Suspension | Front Suspension |

Specification
Application
Metric
English
Brake Caliper to Knuckle
51 Nm
38 lb ft
Brake Bracket to Strut
17 Nm
13 lb ft
Control Arm Front Nut
190 Nm 140 lb ft
Control Arm Rear Nut
123 Nm
Drive Axle Nut
145 Nm 107 lb ft
91 lb ft
Front Wheel Speed Sensor Bracket to Strut
17 Nm
13 lb ft
Hub and Bearing to Knuckle
95 Nm
70 lb ft
Service Ball Joint to Knuckle
68 Nm
50 lb ft
Stabilizer Shaft Link Nut
17 Nm
13 lb ft
Stabilizer Shaft Bracket Bolt
47 Nm
35 lb ft
Strut Housing Tie Bar Through-Bolts
37 Nm
27 lb ft
Strut Mount Nut
75 Nm
55 lb ft
Strut Mount to Body Nuts
24 Nm
18 lb ft
Strut to Knuckle Nuts
190 Nm 140 lb ft
Tie Rod to Knuckle (Do not exceed 70 (52 lb ft) to align cotter pin)
47 Nm
35 lb ft
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2/7/2011
Document ID: 345384
Page 1 of 1
GM SPO Group Numbers

Application
GM SPO Group Number
Stabilizer Shaft
7.241
Stabilizer Shaft Insulator
7.243
Stabilizer Shaft Link
7.244
Steering Knuckle
6.020
Wheel Bearing & Wheel Hub
5.819
Wheel Hub Bolt
5.821
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Document ID: 359966
Page 1 of 4
Stabilizer Shaft Replacement

Removal Procedure
Tools Required
J 24319-B Universal Steering Linkage Puller
1. Raise the vehicle and support the vehicle by the frame. Allow the control arms to hang free.
Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front wheels and tires.
3. Remove the left and right stabilizer link bolts.
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Document ID: 359966
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4. Remove the left and right stabilizer shaft brackets.
5. Use the J 24319-B (1) in order to remove the tie rod ends from the steering knuckle.
6. Disconnect the exhaust pipe from the exhaust manifold.
7. Turn the right strut completely to the right. Slide the stabilizer shaft over the steering
knuckle. Pull down until the stabilizer shaft (3) clears the frame.
8. Remove the stabilizer shaft.
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Document ID: 359966
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1. Install the stabilizer shaft (3) into position.
2. Loosely install the following components:

2.1. The left and right stabilizer shaft insulators
2.2. The brackets
2.3. The bolts
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Document ID: 359966
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3. Loosely install the stabilizer link components.

4. Install the tie rod ends to the knuckles.
Tighten
Tighten the bracket bolts to 47 Nm (35 lb ft).
Tighten the stabilizer link nut to 17 Nm (13 lb ft).
Tighten the tie rod end to knuckle.
The maximum torque for cotter pin alignment is 70 Nm (52 lb ft). Do NOT back off of
the nut in order to insert the cotter pin.
5. Install the cotter pins into the tie rod ends.
6. Install the exhaust pipe to the manifold.
Tighten
Tighten the manifold bolts to 25 Nm (18 lb ft).
7. Install the front wheels and tires.
Tighten
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2/7/2011
Document ID: 359968
Page 1 of 2
Stabilizer Shaft Link Replacement

Removal Procedure
Tools Required
J 24319-B Universal Steering Linkage
1. Raise the vehicle and support the vehicle by the frame. Allow the control arms to hang free.
2. Remove the front wheels and tires.
3. Remove the left and the right stabilizer link bolts.
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Document ID: 359968
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1. Loosely install the stabilizer link components.

2. Install the tie rod ends to the knuckles.
Tighten
Tighten the stabilizer link to 17 Nm (13 lb ft).
3. Install the front wheels and tires.
Tighten
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2/7/2011
Document ID: 359971
Page 1 of 2
Stabilizer Shaft Insulator Replacement

Removal Procedure
1.
2.
3.
4.
Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the stabilizer shaft clamp bolts.
Remove the stabilizer shaft clamp.
Remove the stabilizer shaft rubber insulator.
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Document ID: 359971
Page 2 of 2
1. Install the stabilizer shaft rubber insulator.

2. Install the stabilizer shaft clamp.
3. Install the stabilizer clamp bolts.
Tighten
Tighten the stabilizer clamp bolts to 47 Nm (35 lb ft).
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2/7/2011
Document ID: 359974
Page 1 of 2
Lower Control Arm Ball Joint Replacement

Removal Procedure
Tools Required
J 36226 Ball Joint Separator
Notice: Use only the recommended tools for separating the ball joint from the knuckle.
Failure to use recommended tools may cause damage to the ball joint and seal.
Important: If the ball joint is separated for related suspension/driveline service, the ball
joint seal should be inspected for damage. A damaged seal will cause joint failure. The ball
joint should be replaced if seal damage is found.
1. Raise and support the vehicle by the frame, allowing the control arms to hang free. Refer to
Lifting and Jacking the Vehicle in General Information.
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Wheels and
Tires.
3. Remove the cotter pin from the ball joint and loosen the nut.
4. Using the J 36226 , remove the ball joint from the steering knuckle.
5. Loosen the stabilizer shaft link nut.
Important: Do not damage the drive axle seals when drilling out the ball joint rivets.
6. Drill out three rivets retaining the ball joint.
7. Remove the ball joint from the knuckle and control arm.
2011 General Motors Corporation.
All rights reserved.
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2/7/2011
Document ID: 359974
Page 2 of 2
1. Install the ball joint to the knuckle and align with the holes in the control arm.
2. Install three ball joint bolts facing down, and the nuts.
3. Install the ball joint nut.
Tighten
Tighten the ball joint to control arm nuts to 68 Nm(50 lb ft).
Tighten the stabilizer shaft link nut to 17 Nm (13 lb ft).
Tighten the ball joint nut to 10 Nm (88 lb in). Then tighten an additional 120 degrees
(2 flats on the nut) during which a torque of 55 Nm (41 lb ft) must be obtained.
4. Install the cotter pin. In order to align the slot, tighten the nut up to one more flat.
5. Install the wheel and tire.
Tighten
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2/7/2011
Document ID: 359983
Page 1 of 5
Front Wheel Bearing and Hub Replacement

Removal Procedure
Tools Required
J 28733-B Front Hub Spindle Remover
1. Raise and support the vehicle by the frame, allowing the control arms to hang free. Refer to
Lifting and Jacking the Vehicle in General Information.
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in General
Information.
Clean the drive axle threads of all dirt and lubricate.
3. Remove the drive axle nut. Insert the drift punch or screwdriver into caliper and rotor to
prevent rotor from turning.
4. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
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Document ID: 359983
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5. Remove the ABS front wheel speed sensor connector (1), and unclip from the dust shield.
6. Remove the hub and bearing retaining bolts (6) and the dust shield (1).
7. Place the transmission in Park.
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Document ID: 359983
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Important: The hub and bearing are replaced only as an assembly.

8. Using the J 28733-B , separate the hub and bearing from the drive axle. Clean rust and
foreign material from the knuckle mounting face, bore and chamfer to allow proper seating of
the bearing into the knuckle.
1. Install the hub and bearing to the drive axle. Apply a light coating of grease to the knuckle
bore. If the new hub and bearing has a protective plastic cover, remove it before installation.
Also, do not handle the knuckle or hub assembly by the ABS sensor wire.
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Document ID: 359983
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2. Install the new drive axle nut (5) and draw the hub and bearing (4) onto the axle.
3. Place the transmission in Neutral.
4. Install the dust shield (1), bearing bolts (6) and hub. Take care not to damage the bearing
outboard lip seal.
Tighten
Tighten the hub and bearing bolts to 95 Nm (70 lb ft).
5. Install the ABS front wheel speed sensor connector (1) and clip to the dust shield.
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Document ID: 359983
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6. Install the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Tighten
Tighten the caliper bolts to 51 Nm (38 lb ft).
8. Insert drift punch or screwdriver into the caliper and rotor to prevent the rotor from turning.
Tighten
Tighten the drive axle nut to 145 Nm (107 lb ft).
Tighten
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Document ID: 359990
Page 1 of 5
Steering Knuckle Replacement

Removal Procedure
Tools Required
J 36226 Ball Joint Separator.
J 24319-B Steering Linkage and Tie Rod Puller
J 28733-B Hub and Bearing Puller
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tire and
Wheel.
3. Remove the drive axle nut (2).
4. Remove the brake caliper bolts. Refer to Brake Caliper Replacement in Brakes.
5. Support and hang the caliper away from the brake rotor.
6. Remove the rotor. Refer to Brake Rotor Replacement in Brakes.
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Document ID: 359990
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7. Disconnect the wheel speed sensor connector.
8. Remove the hub and bearing retaining bolts.

9. Use J 28733-B in order to remove the hub and drive axle.
10. Use J 24319-B in order to separate the tie rod from the steering knuckle.
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Document ID: 359990
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11. UsingJ 36226 separate the ball joint from the steering knuckle.
12. Remove the steering knuckle.
1. Install the steering knuckle.

2. Install the lower ball joint. Refer to Lower Control Arm Ball Joint Replacement .
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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener
joint
2/7/2011
Document ID: 359990
Page 4 of 5
3. Install the tie rod.
Tighten
Tighten the tie rod end to knuckle nut to 10 Nm (88 lb in) plus an additional 180 degrees-300 degrees (3--5 flats). For cotter pin alignment, tighten the nut up to, but do not exceed
60 degrees additional rotation. Do not back off nut (2) for cotter pin (1) alignment.
4. Install the hub and bearing to the steering knuckle/drive axle.

5. Install the hub and bearing retaining bolts.
Tighten
Tighten the hub and bearing bolts to 95 Nm (70 lb ft).
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Document ID: 359990
Page 5 of 5
6. Connect the wheel speed sensor connector to the wheel speed sensor.
7. Install the rotor. Refer to Brake Rotor Replacement in Brakes.

8. Install the caliper. Refer to Brake Caliper Replacement in Brakes.
9. Install the drive axle nut (2).
Tighten
Tighten the drive axle nut to 145 Nm (107 lb ft).
Tighten
Tighten the wheel and tire 140 Nm (100 lb ft).
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Document ID: 359994
Page 1 of 4
Lower Control Arm Replacement

Removal Procedure
Tools Required
Failure to use recommended tools may cause damage to the ball joint and seal.
1. Raise the vehicle and suitably support the frame allowing the control arms to hang free.
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove the stabilizer shaft to control arm bolt.

4. Remove the cotter pin and loosen the nut from the ball stud.
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Document ID: 359994
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Notice: Care must be taken not to overextend tri-pot joints. Over extension of the joint
could result in separation of internal components which could go undetected and result in
failure of the joint.
5. Using the J 36226 , remove the ball joint from the steering knuckle.
6. Remove the control arm mounting bolts.

7. Remove the control arm from the frame.
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Document ID: 359994
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1. Install the control arm to the frame.

2. Install the control arm mounting bolts, washers, and nuts.
Important: Do not tighten the control arm nuts at this time. The weight of the vehicle must
be supported by the control arms such that the vehicle design trim heights are obtained
before tightening control arm mounting nuts.
3. Install the stabilizer shaft to control arm.
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Document ID: 359994
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4. Install the ball joint to the steering knuckle.
Tighten
Tighten the stabilizer shaft link assembly to 17 Nm (13 lb ft).
Tighten the joint nut to 10 Nm (88 lb in). Then tighten an additional 120 degrees (2
flats on nut) during which a torque of 55 Nm (41 lb ft) must be obtained.
5. Install the cotter pin. In order to align the slot, tighten the nut up to one more flat.
6. Install the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
Tighten
8. Check the trim height.
Tighten
Tighten the control arm nuts in the following sequence:
Front mounting nut to 190 Nm (140 lb ft).
Rear mounting nut to 123 Nm (91 lb ft).
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2/7/2011
Document ID: 360764
Page 1 of 2
Lower Control Arm Bushings Replacement - Front

Removal Procedure
Tools Required
J 21474-18 Nut
J 21474-5 Bushing Receiver
J 21474-13 Bushing Driver
J 21474-19 Bolt Assembly
1. Remove the control arm from the vehicle. Refer to Lower Control Arm Replacement in Front
Suspension.
2. Assemble the bushing tool as follows:

2.1. Assemble the J 21474-19 through the J 21474-13 with the small end facing the
bushing.
2.2. Assemble J 21474-5 on the front of the bushing.
3. Tighten the bolt until the bushing is driven out of the frame.
4. Remove the bushing driver tool.
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Document ID: 360764
Page 2 of 2
1. Install the bushing to the frame as follows:

1.1. Assemble the J 21474-19 through J 21474-5 with the large end facing the bushing.
1.2. Assemble the large end of the J 21474-13 facing the bushing.
1.3. Connect the J 21474-18 to the threads.
2. Install the J 21474-19 .
Tighten
Tighten bolt J 21474-19 until the bushing is fully seated.
3. Remove the bushing driver tool.
4. Install the control arm to the frame. Refer to Lower Control Arm Replacement in Front
Suspension.
tomsn048@gmail.com
2/7/2011
Document ID: 360003
Page 1 of 2
Wheel Stud Replacement

Removal Procedure
Tools Required
J 6627-A Stud Remover
1. Raise the vehicle. Support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
Wheels.
3.
4.
5.
6.
Remove the brake caliper. Support the caliper.

Remove the rotor. Refer to Brake Rotor Replacement in Brakes.
Use the J 6627-A in order to press out the stud (1).
Remove the stud at the innermost notch in the knuckle, on the caliper side of the knuckle.
tomsn048@gmail.com
2/7/2011
Document ID: 360003
Page 2 of 2
1. Install a new stud. Use washers (1) and wheel nuts (2).
2. Install the rotor.
Tighten
Tighten the caliper bolts to 51 Nm (38 lb ft).
Tighten
tomsn048@gmail.com
2/7/2011
Document ID: 360010
Page 1 of 1
Strut and Knuckle Scribing

Important:
Before servicing the following items, use the scribing procedure:
- The strut mount
- The strut bumper
- The strut shield
- The spring seat
- The spring insulator
- After completing the service, you will be able to return to the original camber setting. Then,
inspect and adjust the toe.
Do not use the scribing procedure when servicing the following components:
- Front Spring
- Strut
- Knuckle
- Control Arm
- Inspect or adjust the camber and the toe after completing the service. Refer to Wheel
Alignment Specifications in Wheel Alignment.
1.
2.
3.
4.
Use a chisel in order to place a mark across the strut/knuckle interface (1).
Scribe the strut flange on the inboard side along the curve of the knuckle (2).
Using a sharp tool, scribe the knuckle along the lower outboard strut radius (3).
During reassembly, carefully match the marks to the components.
tomsn048@gmail.com
2/7/2011
Document ID: 360015
Page 1 of 2
Strut Assembly Replacement

Removal Procedure
1. Loosen the strut housing tie bar through-bolts on both ends of the tie bar.
2. If CCR equipped, disconnect the CCR electrical connector.
3. Remove the three strut mounts, strut to body.
4. Raise and suitably support the vehicle by the frame, allowing the control arms to hang free.
5. Remove the wheel and tire.
6. Remove the ABS front wheel speed sensor connector.
7. Remove the speed sensor bracket from the strut.
8. Remove the brake line bracket from the strut.
Notice: The knuckle must be retained after the strut-to-knuckle bolts have been removed.
Failure to observe this may cause ball joint and/or wheel drive shaft damage.
9. Remove the strut to knuckle bolts.
Notice: Care should be taken to avoid chipping or cracking the spring coating when handling
the front suspension coil spring.
10. Remove the strut from the vehicle.
tomsn048@gmail.com
2/7/2011
Document ID: 360015
Page 2 of 2
1. Install the strut into place

2. Install the washer and tie bar.
3. Install the three strut mount nuts.
Tighten
Tighten the strut mount nuts to 24 Nm (18 lb ft).
4.
5.
6.
7.
8.
Tighten the tie bar through-bolts (outboard first) to 37 (27 lb ft).

If CCR equipped, connect the CCR electrical connector.
Install the strut to knuckle bolts.
Install the brake line bracket to the strut.
Install the speed sensor bracket to the strut.
Install the speed sensor connector.
Tighten
Tighten the strut to knuckle bolts to 190 Nm (140 lb ft).
Tighten the brake line and speed sensor bracket bolts to 17 Nm (13 lb ft).
Tighten
tomsn048@gmail.com
2/7/2011
Document ID: 360021
Page 1 of 5
Strut, Strut Component, and Spring Replacement

Removal Procedure
Tools Required
J 3289-20 Holding Fixture
J 34013-B Strut Compressor
J 34013-38 Alignment Rod
the front suspension coil spring. Failure to observe this notice may result in spring breakage.
Important: Remove the strut from the vehicle in order to perform this procedure. Refer to
Strut Assembly Replacement in Front Suspension.
1. Install the strut (1) into the J 34013-B .
Tighten the nuts (2) flush with the strut compressor.
Install the locking pins (4) through the strut.
2. Turn the compressor forcing screw (3) until the spring compresses slightly.
tomsn048@gmail.com
2/7/2011
Document ID: 360021
Page 2 of 5
3. Use a socket (3) in order to hold the strut shaft from turning.
Remove the 24 mm strut shaft nut using a 24 mm wrench (2).
4. Install the J 34013-38 in order to help guide the strut shaft out of the assembly.
tomsn048@gmail.com
2/7/2011
Document ID: 360021
Page 3 of 5
the front suspension coil spring. Failure to observe this notice may result in spring breakage.
5. Loosen the compressor screw (3) while guiding the strut shaft (1) out of the assembly.
Continue loosening the compressor screw until the strut and the spring may be removed.
Tools Required
J 34013-B Strut Compressor
J 34013-20 Damper Rod Clamp
J 34013-38 Alignment Rod
tomsn048@gmail.com
2/7/2011
Document ID: 360021
Page 4 of 5
1. Install the strut in the J 34013-B with the J 34013-20 clamped on the strut shaft (1) in the
strut compressor.
Important:
Ensure that the flat on the upper spring seat faces out from the centerline of the
vehicle. When you mount the spring seat in the strut compressor, ensure that the
spring seat faces in the same direction as the steering knuckle mounting flange.
If the bearing had been removed from the upper spring seat, install the bearing into the
upper spring seat in the same orientation as it had been. Also, install the bearing in the
spring seat before attaching to the strut mount.
2. Install the spring over the strut in the correct position.
3. Move the assembly upright in the strut compressor.
4. Install the upper locking pin (2).
tomsn048@gmail.com
2/7/2011
Document ID: 360021
Page 5 of 5
5. Install the rod J 34013-38 into the strut guide strut shaft.
6. Start turning the compressor screw clockwise on the J 34013-B , while guiding the J 3401338 to the center strut shaft in the assembly.
7. Continue to turn the compressor forcing screw (3) on the strut compressor until the strut
shaft threads are visible through the top of the strut assembly.
8. Install the washer and the nut.
9. Remove the clamp J 34013-20 from the strut shaft.
Tighten
Tighten the strut mount nut to 75 Nm (55 lb ft) while holding the strut shaft with the socket.
10. Remove the strut from the strut compressor.
tomsn048@gmail.com
2/7/2011
GENERIC OBD-11 TROUBLE CODES

OTC CODES P0001 to P0099
P0010 ... .'A' Camshaft Position Actuator Circuit (Bank 1)

P0011 ... .'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
P0012 ... .'A' Camshaft Position - Timing Over-Retarded (Bank 1)
P0013 ... .'B' Camshaft Position - Actuator Circuit (Bank 1)
P0014 ... .'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 1)
P0015 ... .'B' Camshaft Position -Timing Over-Retarded (Bank 1)
P0020 ... .'A' Camshaft Position Actuator Circuit (Bank 2)
P0021 ... .'A' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
P0022 ... .'A' Camshaft Position - Timing Over-Retarded (Bank 2)
P0023 ... .'B' Camshaft Position -Actuator Circuit (Bank 2)
P0024 ... .'B' Camshaft Position - Timing Over-Advanced or System Performance (Bank 2)
P0025 ... .'B' Camshaft Position - Timing Over-Retarded (Bank 2)
P0030 .... H02S Heater Control Circuit (Bank 1 Sensor 1)
P0031 .... H02S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 .... H02S Heater Control Circuit High (Bank 1 Sensor 1)
P0033 ... .Turbo Charger Bypass Valve Control Circuit
P0034 ... .Turbo Charger Bypass Valve Control Circuit Low
P0035 ... .Turbo Charger Bypass Valve Control Circuit High

P0050 .... H02S Heater Control Circuit (Bank 2 .... Sensor 1)
P0065 .... Air Assisted Injector Control Range/Performance
P0066 .... Air Assisted Injector Control Circuit or Circuit Low
P0067 .... Air Assisted Injector Control Circuit High
P0070 .... Ambient Air Temperature Sensor Circuit
P0071 .... Ambient Air Temperature Sensor Range/Performance
P0072 .... Ambient Air Temperature Sensor Circuit Low Input
P0073 .... Ambient Air Temperature Sensor Circuit High Input
P007 4 .... Ambient Air Temperature Sensor Circuit Intermittent
P0075 .... lntake Valve Control Solenoid Circuit (Bank 1)
P0076 .... lntake Valve Control Solenoid Circuit Low (Bank 1)
P0077 .... lntake Valve Control Solenoid Circuit High (Bank 1)
P0078 .... ExhaustValve Control Solenoid Circuit (Bank 1)
P0079 .... Exhaust Valve Control Solenoid Circuit Low (Bank 1)
P0080 .... Exhaust Valve Control Solenoid Circuit High (Bank 1)
P0081 .... lntake valve Control Solenoid Circuit (Bank 2)
P0082 .... lntake Valve Control Solenoid Circuit Low (Bank 2)

P0083 .... lntake Valve Control Solenoid Circuit High (Bank 2)
P0084 .... Exhaust Valve Control Solenoid Circuit (Bank 2)
P0085 .... Exhaust Valve Control Solenoid Circuit Low (Bank 2)
P0086 .... Exhaust Valve Control Solenoid Circuit High (Bank 2)
P0100 .... Mass or Volume Air Flow Circuit
P0101 .... Mass or Volume Air Flow Circuit Range/Performance Problem
P0102 .... Mass or Volume Air Flow Circuit Low Input
P0103 .... Mass or Volume Air Flow Circuit High Input
P0104 .... Mass or Volume Air Flow Circuit Intermittent
P0105 .... Manifold Absolute Pressure/Barometric Pressure Circuit
P0106 .... Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance Problem
P0107 .... Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
P0108 .... Manifold Absolute Pressure/Barometric Pressure Circuit High Input
P0109 .... Manifold Absolute Pressure/Barometric Pressure Circuit Intermittent
P0110 .... lntake Air Temperature Circuit
P0111 .... lntake Air Temperature Circuit Range/Performance Problem
P0112 .... lntake Air Temperature Circuit Low Input
P0113 .... lntake Air Temperature Circuit High Input
P0114 .... lntake Air Temperature Circuit Intermittent
P0115 .... Engine Coolant Temperature Circuit
P0116 .... Engine Coolant Temperature Circuit Range/Performance Problem
P0117 .... Engine Coolant Temperature Circuit Low Input
P0118 .... Engine Coolant Temperature Circuit High Input
P0119 .... Engine Coolant Temperature Circuit Intermittent
P0120 ... .Throttle/Pedal Position Sensor/Switch A Circuit

P0121 ... .Throttle/Pedal Position Sensor/Switch A Circuit Range/Performance Problem
P0122 ... .Throttle/Pedal Position Sensor/Switch A Circuit Low Input
P0123 ... .Throttle/Pedal Position Sensor/Switch A Circuit High Input
P0124 ... .Throttle/Pedal Position Sensor/Switch A Circuit Intermittent
P0125 .... lnsufficient Coolant Temperature for Closed Loop Fuel Control
P0126 .... lnsufficient Coolant Temperature for Stable Operation
P0127 .... lntake Air Temperature Too High
P0128 .... Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
P0130 .... 02 Sensor Circuit (Bank 1 Sensor 1)
P0131 .... 02 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132 .... 02 Sensor Circuit High Voltage (Bank 1 Sensor 1)
P0133 .... 02 Sensor Circuit Slow Response (Bank 1 Sensor 1)
P0134 .... 02 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
P0135 .... 02 Sensor Heater Circuit (Bank 1 Sensor 1)
P0136 .... 02 Sensor Circuit Malfunction (Bank 1 Sensor 2)

P0148 .... Fuel Delivery Error
P0149 .... Fuel Timing Error
P0150 .... 02 Sensor Circuit (Bank 2 Sensor 1)
P0152 .... 02 Sensor Circuit High Voltage (Bank 2Sensor1)
P0168 .... Fuel Temperature Too High
P0169 .... lncorrect Fuel Composition
P0170 .... Fuel Trim (Bank 1)
P0171 .... System too Lean (Bank 1)

P0172 .... System too Rich (Bank 1)
P0173 .... Fuel Trim Malfunction (Bank 2)
P0174 .... System too Lean (Bank 2)
P0175 .... System too Rich (Bank2)
P0176 .... Fuel Composition Sensor Circuit
P0177 .... Fuel Composition Sensor Circuit Range/Performance
P0178 .... Fuel Composition Sensor Circuit Low Input
P0179 .... Fuel Composition Sensor Circuit High Input
P0180 .... Fuel Temperature Sensor A Circuit
P0181 .... Fuel Temperature Sensor A Circuit Range/Performance
P0182 .... Fuel Temperature Sensor A Circuit Low Input
P0183 .... Fuel Temperature Sensor A Circuit High Input
P0184 .... Fuel Temperature Sensor A Circuit Intermittent
P0185 .... Fuel Temperature Sensor B Circuit
P0186 .... Fuel Temperature Sensor B Circuit Range/Performance
P0187 .... Fuel Temperature Sensor B Circuit Low Input
P0188 .... Fuel Temperature Sensor B Circuit High Input
P0189 .... Fuel Temperature Sensor B Circuit Intermittent
P0190 .... Fuel Rail Pressure Sensor Circuit
P0191 .... Fuel Rail Pressure Sensor Circuit Range/Performance
P0192 .... Fuel Rail Pressure Sensor Circuit Low In put
P0193 .... Fuel Rail Pressure Sensor Circuit High Input
P0194 .... Fuel Rail Pressure Sensor Circuit Intermittent
P0195 .... Engine Oil Temperature Sensor
P0196 .... Engine Oil Temperature Sensor Range/Performance

P0197 .... Engine Oil Temperature Sensor Low
P0198 .... Engine Oil Temperature Sensor High
P0199 .... Engine Oil Temperature Sensor Intermittent
P0200 .... lnjector Circuit
P0201 .... lnjector Circuit - Cylinder 1
P0207 .... Injector Circuit - Cylinder 7
P0213 .... Cold Start Injector 1
P0214 .... Cold Start Injector 2
P0215 .... Engine Shutoff Solenoid
P0216 .... lnjector/lnjection Timing Control Circuit
P0217 .... Engine Coolant Over Temperature Condition
P0218 ... .Transmission Fluid Over Temperature Condition
P0219 .... Engine Over Speed Condition
P0220 ... .Throttle/Pedal Position Sensor/Switch 'B' Circuit
P0221 ... .Throttle/Pedal Position Sensor/Switch 'B' Circuit Range/Performance Problem

P0222 ... .Throttle/Pedal Position Sensor/Switch 'B' Circuit Low Input
P0223 ... .Throttle/Pedal Position Sensor/Switch 'B' Circuit High Input
P0224 ... .Throttle/Pedal Position Sensor/Switch 'B' Circuit Intermittent
P0225 ... .Throttle/Pedal Position Sensor/Switch 'C' Circuit
P0226 ... .Throttle/Pedal Position Sensor/Switch 'C' Circuit Range/Performance Problem
P0227 ... .Throttle/Pedal Position Sensor/Switch 'C' Circuit Low Input
P0228 ... .Throttle/Pedal Position Sensor/Switch 'C' Circuit High Input
P0229 ... .Throttle/Pedal Position Sensor/Switch 'C' Circuit Intermittent
P0230 .... Fuel Pump Primary Circuit
P0231 .... Fuel Pump Secondary Circuit Low
P0232 .... Fuel Pump Secondary Circuit High
P0233 .... Fuel Pump Secondary Circuit Intermittent
P0234 ... .Turbo/Super Charger Overboost Condition
P0235 ... .Turbo/Super Charger Boost Sensor 'A' Circuit
P0236 ... .Turbo/Super Charger Boost Sensor 'A' Circuit Range/Performance
P0237 ... .Turbo/Super Charger Boost Sensor 'A' Circuit Low
P0238 ... .Turbo/Super Charger Boost Sensor 'A' Circuit High
P0239 ... .Turbo/Super Charger Boost Sensor 'B' Circuit
P0240 ... .Turbo/Super Charger Boost Sensor 'B' Circuit Range/Performance
P0241 ... .Turbo/Super Charger Boost Sensor 'B' Circuit Low
P0242 ... .Turbo/Super Charger Boost Sensor 'B' Circuit High
P0243 ... .Turbo/Super Charger Wastegate Solenoid 'A'
P0244 ... .Turbo/Super Charger Wastegate Solenoid 'A' Range/Performance
P0245 ... .Turbo/Super Charger Wastegate Solenoid 'A' Low
P0246 ... .Turbo/Super Charger Wastegate Solenoid 'A' High

P0247 ... .Turbo/Super Charger Wastegate Solenoid 'B'
P0248 ... .Turbo/Super Charger Wastegate Solenoid 'B' Range/Performance
P0249 ... .Turbo/Super Charger Wastegate Solenoid 'B' Low
P0250 ... .Turbo/Super Charger Wastegate Solenoid 'B' High
P0251 .... lnjection Pump Fuel Metering Control 'A' (Cam/rotor/Injector)
P0252 .... lnjection Pump Fuel Metering Control 'A' Range/Performance (Cam/Rotor/Injector)
P0253 .... lnjection Pump Fuel Metering Control 'A' Low (Cam/Rotor/Injector)
P0254 .... lnjection Pump Fuel Metering Control 'A' High (Cam/Rotor/Injector)
P0255 .... lnjection Pump Fuel Metering Control 'A' Intermittent (Cam/Rotor/Injector)
P0256 .... lnjection Pump Fuel Metering Control 'B' (Cam/Rotor/Injector)
P0257 .... Injection Pump Fuel Metering Control 'B' Range/Performance (Cam/Rotor/Injector)
P0258 .... lnjection Pump Fuel Metering Control 'B' Low (Cam/Rotor/Injector)
P0259 .... lnjection Pump Fuel Metering Control 'B' High (Cam/Rotor/Injector)
P0260 .... lnjection Pump Fuel Metering Control 'B' Intermittent (Cam/Rotor/Injector)
P0261 .... Cylinder 1 Injector Circuit Low
P0262 .... Cylinder 1 Injector Circuit High
P0263 .... Cylinder 1 Contribution/Balance
P0269 .... Cylinder 4 .... Contribution/Balance

P0276 .... Cylinder 6 .... lnjector Circuit Low
P0277 .... Cylinder 6 .... lnjector Circuit High
P0288 .... Cylinder 10 .... lnjector Circuit Low
P0289 .... Cylinder 10 .... lnjector Circuit High
P0290 .... Cylinder 1O.... Contribution/Balance

P0298 .... Engine Oil Over Temperature
P0300 .... Random/Multiple Cylinder Misfire Detected
P0301 .... Cylinder 1 Misfire Detected
P0310 .... Cylinder 10 .... Misfire Detected
P0313 .... Misfire Detected with Low Fuel
P0314 .... Single Cylinder Misfire (Cylinder not Specified)
P0320 .... lgnition/Distributor Engine Speed Input Circuit
P0321 .... lgnition/Distributor Engine Speed Input Circuit Range/Performance
P0322 .... lgnition/Distributor Engine Speed Input Circuit No Signal
P0323 .... lgnition/Distributor Engine Speed Input Circuit Intermittent
P0324 .... Knock Control System Error
P0325 .... Knock Sensor 1 Circuit (Bank 1 or Single Sensor)
P0326 .... Knock Sensor 1 Circuit Range/Performance (Bank 1 or Single Sensor)
P0327 .... Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
P0328 .... Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
P0329 .... Knock Sensor 1 Circuit Input Intermittent (Bank 1 or Single Sensor)
P0330 .... Knock Sensor 2 Circuit (Bank 2)
P0331 .... Knock Sensor 2 Circuit Range/Performance (Bank 2)
P0332 .... Knock Sensor 2 Circuit Low Input (Bank 2)
P0333 .... Knock Sensor 2 Circuit High Input (Bank 2)
P0334 .... Knock Sensor 2 Circuit Input Intermittent (Bank 2)
P0335 .... Crankshaft Position Sensor A Circuit
P0336 .... Crankshaft Position Sensor A Circuit Range/Performance
P0337 .... Crankshaft Position Sensor A Circuit Low Input
P0338 .... Crankshaft Position Sensor A Circuit High Input
P0339 .... Crankshaft Position Sensor A Circuit Intermittent
P0340 .... Camshaft Position Sensor 'A' Circuit (Bank 1 or Single Sensor)
P0341 Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 1 or Single Sensor)
P0342 .... Camshaft Position Sensor 'A' Circuit Low Input (Bank 1 or Single Sensor)
P0343 .... Camshaft Position Sensor 'A' Circuit High Input (Bank 1 or Single Sensor)
P0344 .... Camshaft Position Sensor 'A' Circuit Intermittent (Bank 1 or Single Sensor)
P0345 .... Camshaft Position Sensor 'A' Circuit (Bank 2)
P0346 .... Camshaft Position Sensor 'A' Circuit Range/Performance (Bank 2)
P0347 .... Camshaft Position Sensor 'A' Circuit Low Input (Bank 2)
P0348 .... Camshaft Position Sensor 'A' Circuit High Input (Bank 2)
P0349 .... Camshaft Position Sensor 'A' Circuit Intermittent (Bank 2)
P0350 .... lgnition Coil Primary/Secondary Circuit
P0351 .... lgnition Coil 'A' Primary/Secondary Circuit
P0352 .... lgnition Coil 'B' Primary/Secondary Circuit
P0353 .... lgnition Coil 'C' Primary/Secondary Circuit

P0354 .... lgnition Coil 'D' Primary/Secondary Circuit
P0355 .... lgnition Coil 'F' Primary/Secondary Circuit
P0356 .... lgnition Coil 'F' Primary/Secondary Circuit
P0357 .... lgnition Coil 'G' Primary/Secondary Circuit
P0358 .... lgnition Coil 'H' Primary/Secondary Circuit
P0359 .... lgnition Coil 'I' Primary/Secondary Circuit
P0360 .... lgnition Coil 'J' Primary/Secondary Circuit
P0361 .... lgnition Coil 'K Primary/Secondary Circuit
P0362 .... lgnition Coil 'L' Primary/Secondary Circuit
P0365 .... Camshaft Position Sensor 'B' Circuit (Bank 1)
P0366 .... Camshaft Position Sensor 'B' Circuit Range/Performance (Bank 1)
P0367 .... Camshaft Position Sensor 'B' Circuit Low Input (Bank 1)
P0368 .... Camshaft Position Sensor 'B' Circuit High Input (Bank 1)
P0369 .... Camshaft Position Sensor 'B' Circuit Intermittent (Bank 1)
P0370 ... .Timing Reference High Resolution Signal 'A'
P0371 ... .Timing Reference High Resolution Signal 'A' Too Many Pulses
P0372 ... .Timing Reference High Resolution Signal 'A' Too Few Pulses
P0373 ... .Timing Reference High Resolution Signal 'A' lntermittenUErratic Pulses
P0374 ... .Timing Reference High Resolution Signal 'A' No Pulse
P0375 ... .Timing Reference High Resolution Signal 'B'
P0376 ... .Timing Reference High Resolution Signal 'B' Too Many Pulses
P0377 ... .Timing Reference High Resolution Signal 'B' Too Few Pulses
P0378 ... .Timing Reference High Resolution Signal 'B' lntermittenUErratic Pulses
P0379 ... .Timing Reference High Resolution Signal 'B' No Pulses
P0380 .... Glow Plug/Heater Circuit 'A'

P0381 .... Glow Plug/Heater Indicator Circuit
P0382 .... Glow Plug/Heater Circuit 'B'
P0385 .... Crankshaft Position Sensor 'B' Circuit
P0386 .... Crankshaft Position Sensor 'B' Circuit Range/Performance
P0387 .... Crankshaft Position Sensor 'B' Circuit Low Input
P0388 .... Crankshaft Position Sensor 'B' Circuit High Input
P0389 .... Crankshaft Position Sensor 'B' Circuit Intermittent
P0390 .... camshaft Position Sensor 'B' Circuit
P0391 .... Camshaft Position Sensor 'B' circuit Range/Performance (Bank 2)
P0392 .... Camshaft Position Sensor 'B' Circuit Low Input (Bank 2)
P0393 .... Camshaft Position Sensor 'B' Circuit High Input (Bank 2)
P0394 .... Camshaft Position Sensor 'B' Circuit Intermittent (Bank 2)
P0400 .... Exhaust Gas Recirculation Flow
P0401 .... Exhaust Gas Recirculation Flow Insufficient Detected
P0402 .... Exhaust Gas Recirculation Flow Excessive Detected
P0403 .... Exhaust Gas Recirculation Control Circuit
P0404 .... Exhaust Gas Recirculation Control Circuit Range/Performance
P0405 .... Exhaust Gas Recirculation Sensor 'A' Circuit Low
P0406 .... Exhaust Gas Recirculation Sensor 'A' Circuit High
P0407 .... Exhaust Gas Recirculation Sensor 'B' Circuit Low
P0408 .... Exhaust Gas Recirculation Sensor 'B' Circuit High
P0409 .... Exhaust Gas Recirculation Sensor 'A' Circuit
P0410 .... Secondary Air Injection System
P0411 .... Secondary Air Injection System Incorrect Flow Detected
P0412 .... Secondary Air Injection System Switching Valve 'A' Circuit
P0413 .... Secondary Air Injection System Switching Valve 'A' Circuit Open
P0414 .... Secondary Air Injection System Switching Valve 'A' Circuit Shorted
P0415 .... Secondary Air Injection System Switching Valve 'B' Circuit
P0416 .... secondary Air Injection System Switching Valve 'B' Circuit Open
P0417 .... secondary Air Injection System Switching Valve 'B' Circuit Shorted
P0416 .... Secondary Air Injection System Relay 'A' Circuit
P0419 .... Secondary Air injection System Relay 'B' Circuit
P0420 .... Catalyst System Efficiency Below Threshold (Bank 1)
P0421 .... Warm Up Catalyst Efficiency Below Threshold (Bank 1)
P0422 .... Main Catalyst Efficiency Below Threshold (Bank 1)
P0423 .... Heated Catalyst Efficiency Below Threshold (Bank 1)
P0424 .... Heated Catalyst Temperature Below Threshold (Bank 1)
P0425 .... Catalyst Temperature Sensor (Bank 1)
P0426 .... Catalyst Temperature Sensor Range/Performance (Bank 1)
P0427 .... Catalyst Temperature Sensor Low Input (Bank 1)
P0428 .... Catalyst Temperature Sensor High Input (Bank 1)
P0429 .... Catalyst Heater Control Circuit (Bank 1)
P0430 .... Catalyst System Efficiency Below Threshold (Bank 2)
P0431 .... Warm Up Catalyst Efficiency Below Threshold (Bank 2)
P0432 .... Main Catalyst Efficiency Below Threshold (Bank 2)
P0433 .... Heated Catalyst Efficiency Below Threshold (Bank 2)
P0434 .... Heated Catalyst Temperature Below Threshold (Bank 2)
P0435 .... Catalyst Temperature Sensor (Bank 2)
P0436 .... Catalyst Temperature Sensor Range/Performance (Bank 2)
P0437 .... Catalyst Temperature Sensor Low Input (Bank 2)

P0438 .... Catalyst Temperature Sensor High Input (Bank 2)
P0439 .... Catalyst Heater Control Circuit (Bank 2)
P0440 .... Evaporative Emission Control System
P0441 .... Evaporative Emission Control System Incorrect Purge Flow
P0442 .... Evaporative Emission Control System Leak Detected (small leak)
P0443 .... Evaporative Emission Control System Purge Control Valve Circuit
P0444 .... Evaporative Emission Control System Purge Control Valve Circuit Open
P0445 .... Evaporative Emission Control System Purge Control Valve Circuit Shorted
P0446 .... Evaporative Emission Control System Vent Control Circuit
P0447 .... Evaporative Emission Control System Vent Control Circuit Open
P0448 .... Evaporative Emission Control System Vent Control Circuit Shorted
P0449 .... Evaporative Emission Control System Vent Valve/Solenoid Circuit
P0450 .... Evaporative Emission Control System Pressure Sensor
P0451 .... Evaporative Emission Control System Pressure Sensor Range/Performance
P0452 .... Evaporative Emission Control System Pressure Sensor Low Input
P0453 .... Evaporative Emission Control System Pressure Sensor High input
P0454 .... Evaporative Emission Control System Pressure Sensor Intermittent
P0455 .... Evaporative Emission Control System Leak Detected (gross leak)
P0456 .... Evaporative Emission Control System Leak Detected (very small leak)
P0457 .... Evaporative Emission Control System Leak Detected (fuel cap loose/off)
P0460 .... Fuel Level Sensor Circuit
P0461 .... Fuel Level Sensor Circuit Range/Performance
P0462 .... Fuel Level Sensor Circuit Low Input
P0463 .... Fuel Level Sensor Circuit High Input
P0464 .... Fuel Level Sensor Circuit Intermittent

P0465 .... EVAP Purge Flow Sensor Circuit
P0466 .... EVAP Purge Flow Sensor Circuit Range/Performance
P0467 .... EVAP Purge Flow Sensor Circuit Low Input
P0468 .... EVAP Purge Flow Sensor Circuit High Input
P0469 .... EVAP Purge Flow Sensor Circuit Intermittent
P0470 .... Exhaust Pressure Sensor
P0471 .... Exhaust Pressure Sensor Range/Performance
P0472 .... Exhaust Pressure Sensor Low
P0473 .... Exhaust Pressure Sensor High
P0474 .... Exhaust Pressure Sensor Intermittent
P0475 .... Exhaust Pressure Control Valve
P0476 .... Exhaust Pressure Control Valve Range/Performance
P0477 .... Exhaust Pressure Control Valve Low
P0478 .... Exhaust Pressure Control Valve High
P0479 .... Exhaust Pressure Control Valve Intermittent
P0480 .... Cooling Fan 1 Control Circuit
P0483 .... Cooling Fan Rationality Check
P0484 .... Cooling Fan Circuit Over Current
P0485 .... Cooling Fan Power/Ground Circuit
P0486 .... Exhaust Gas Recirculation Sensor 'B' Circuit
P0487 .... Exhaust Gas Recirculation Throttle Position Control Circuit
P0488 .... Exhaust Gas Recirculation Throttle Position Control Range/Performance
P0491 .... Secondary Air Injection System (Bank 1)

P0492 .... Secondary Air Injection System (Bank
P0500 ... .Vehicle Speed Sensor
P0501 ... .Vehicle Speed Sensor Range/Performance
P0502 ... .Vehicle Speed Sensor Circuit Low Input
P0503 ... .Vehicle Speed Sensor lntermittenUErratic/High
P0505 .... ldle Control System
P0506 .... ldle Control System RPM Lower Than Expected
P0507 .... ldle Control System RPM HigherThan Expected
P0508 .... ldle Control System Circuit Low
P0509 .... ldle Control System Circuit High
P0510 .... Closed Throttle Position Switch
P0512 .... Starter Request Circuit
P0513 .... lncorrect Immobilizer Key
P0515 .... Battery Temperature Sensor Circuit
P0516 .... Battery Temperature Sensor Circuit Low
P0517 .... Battery Temperature Sensor Circuit High
P0520 .... Engine Oil Pressure Sensor/Switch Circuit
P0521 .... Engine Oil Pressure Sensor/Switch Range/Performance
P0522 .... Engine Oil Pressure Sensor/Switch Low Voltage
P0523 .... Engine Oil Pressure Sensor/Switch High Voltage
P0524 .... Engine Oil Pressure Too Low
P0530 .... A/C Refrigerant Pressure Sensor Circuit
P0531 .... A/C Refrigerant Pressure Sensor Circuit Range/Performance
P0532 .... A/C Refrigerant Pressure Sensor Circuit Low Input
P0533 .... A/C Refrigerant Pressure Sensor Circuit High Input

P0534 .... Air Conditioner Refrigerant Charge Loss
P0540 .... lntake Air Heater Circuit
P0541 .... lntake Air Heater Circuit Low
P0542 .... lntake Air Heater Circuit High
P0544 .... Exhaust Gas Temperature Sensor Circuit (Bank 1)
P0545 .... Exhaust Gas Temperature Sensor Circuit Low (Bank 1)
P0546 .... Exhaust Gas Temperature Sensor Circuit High (Bank 1)
P0547 .... Exhaust Gas Temperature Sensor Circuit (Bank 2)
P0548 .... Exhaust Gas Temperature Sensor Circuit Low (Bank 2)
P0549 .... Exhaust Gas Temperature Sensor Circuit High (Bank 2)
P0550 .... Power Steering Pressure Sensor Circuit
P0551 .... Power Steering Pressure Sensor Circuit Range/Performance
P0552 .... Power Steering Pressure Sensor Circuit Low Input
P0553 .... Power Steering Pressure Sensor Circuit High Input
P0554 .... Power Steering Pressure Sensor Circuit Intermittent
P0560 .... System Voltage
P0561 .... System Voltage Unstable
P0562 .... System Voltage Low
P0563 .... System Voltage High
P0564 .... Cruise Control Multi-Function Input Signal
P0565 .... Cruise Control On Signal
P0566 .... Cruise Control Off Signal
P0567 .... Cruise Control Resume Signal
P0568 .... Cruise Control Set Signal
P0569 .... Cruise Control Coast Signal

P0570 .... Cruise Control Accel Signal
P0571 .... Cruise Control/Brake Switch A Circuit
P0572 .... Cruise Control/Brake Switch A Circuit Low
P0573 .... Cruise Control/Brake Switch A Circuit High
P0574 .... Cruise Control System - Vehicle Speed Too High
P0575 .... Cruise Control Input Circuit
P0576 .... Cruise Control Input Circuit Low
P0577 .... Cruise Control input Circuit High
P0600 .... Serial Communication Link
P0601 .... lnternal Control Module Memory Check Sum Error
P0602 .... Control Module Programming Error
P0603 .... lnternal Control Module Keep Alive Memory (KAM) Error
P0604 .... lnternal Control Module Random Access Memory (RAM) Error
P0605 .... lnternal Control Module Read Only Memory (ROM) Error
P0606 .... ECM/PCM Processor
P0607 .... Control Module Performance
P0608 .... Control Module VSS Output 'A'
P0609 .... Control Module VSS Output 'B'
P0610 .... Control Module Vehicle Options Error
P0615 .... Starter Relay Circuit
P0616 .... Starter Relay Circuit Low
P0617 .... Starter Relay Circuit High
P0618 .... Alternative Fuel Control Module KAM Error
P0619 .... Alternative Fuel Control Module RAM/ROM Error
P0620 .... Generator Control Circuit

P0621 .... Generator Lamp 'L' Terminal Control Circuit
P0622 .... Generator Field 'F' Terminal Control Circuit
P0623 .... Generator Lamp Control Circuit
P0624 .... Fuel Cap Lamp Control Circuit
P0630 ... .VIN Not Programmed or Mismatch - ECM/PCM
P0631 ... .VIN Not Programmed or Mismatch - TCM
P0635 .... Power Steering Control Circuit
P0836 .... Power Steering Control Circuit Low
P0637 .... Power Steering Control Circuit High
P0638 ... .Throttle Actuator Control Range/Performance (Bank 1)
P0639 ... .Throttle Actuator Control Range/Performance (Bank 2)
P0640 .... lntake Air Heater Control Circuit
P0645 .... A/C Clutch Relay Control Circuit
P0646 .... A/C Clutch Relay Control Circuit Low
P0647 .... A/C Clutch Relay Control Circuit High
P0648 .... lmmobilizer Lamp Control Circuit
P0649 .... Speed Control Lamp Control Circuit
P0650 .... Malfunction Indicator Lamp (ML) Control Circuit
P0654 .... Engine RPM Output Circuit
P0655 .... Engine Hot Lamp Output Control Circuit
P0656 .... Fuel Level Output Circuit
P0660 .... lntake Manifold Tuning Valve Control Circuit (Bank 1)
P0661 .... lntake Manifold Tuning Valve Control Circuit Low (Bank 1)
P0662 .... lntake Manifold Tuning Valve Control Circuit High (Bank 1)
P0663 .... lntake Manifold Tuning Valve Control Circuit (Bank 2)

P0664 .... lntake Manifold Tuning Valve Control Circuit Low (Bank 2)
P0665 .... lntake Manifold Tuning Valve Control Circuit High (Bank 2)
P0700 ... .Transmission Control System (MIL Request)
P0701 ... .Transmission Control System Range/Performance
P0702 ... .Transmission Control System Electrical
P0703 ... .Torque Converter/Brake Switch B Circuit
P0704 .... Clutch Switch In put Circuit Malfunction
P0705 ... .Transmission Range Sensor Circuit Malfunction (PRNDL Input)
P0706 ... .Transmission Range Sensor Circuit Range/Performance
P0707 ... .Transmission Range Sensor Circuit Low Input
P0708 ... .Transmission Range Sensor Circuit High Input
P0709 ... .Transmission Range Sensor Circuit intermittent
P0710 ... .Transmission Fluid Temperature Sensor Circuit
P0711 ... .Transmission Fluid Temperature Sensor Circuit Range/Performance
P0712 ... .Transmission Fluid Temperature Sensor Circuit Low Input
P0713 ... .Transmission Fluid Temperature Sensor Circuit High Input
P0714 ... .Transmission Fluid Temperature Sensor Circuit Intermittent
P0715 .... lnput/Turbine Speed Sensor Circuit
P0716 .... lnput/Turbine Speed Sensor Circuit Range/Performance
P0717 .... Input/Turbine Speed Sensor Circuit No Signal
P0718 .... lnput/Turbine Speed Sensor Circuit Intermittent
P0719 ... .Torque Converter/Brake Switch B Circuit Low
P0720 .... 0utput Speed Sensor Circuit
P0721 .... Output Speed Sensor Circuit Range/Performance
P0722 .... 0utput Speed Sensor Circuit No Signal

P0723 .... 0utput Speed Sensor Circuit Intermittent
P0724 ... .Torque Converter/Brake Switch B Circuit High
P0725 .... Engine Speed Input Circuit
P0726 .... Engine Speed Input Circuit Range/Performance
P0727 .... Engine Speed Input Circuit No Signal
P0728 .... Engine Speed Input Circuit Intermittent
P0730 .... lncorrect Gear Ratio
P0731 .... Gear 1 Incorrect Ratio
P0736 .... Reverse Incorrect Ratio
P0737 ... .TCM Engine Speed Output Circuit
P0739 ... .TCM Engine Speed Output Circuit Low
P0739 ... .TCM Engine Speed Output Circuit High
P0740 ... .Torque Converter Clutch Circuit
PO? 41 ... .Torque Converter Clutch Circuit Performance or Stuck Off
P0742 ... .Torque Converter Clutch Circuit Stuck On
P0743 ... .Torque Converter Clutch Circuit Electrical
P0744 ... .Torque Converter Clutch Circuit Intermittent
P0745 .... Pressure Control Solenoid 'A'
P0746 .... Pressure Control Solenoid 'A' Performance or Stuck Off
P0747 .... Pressure Control Solenoid 'A' Stuck On
P0748 .... Pressure Control Solenoid 'A' Electrical

P0749 .... Pressure Control Solenoid 'A' Intermittent
P0750 .... Shift Solenoid 'A'
P0751 .... Shift Solenoid 'A' Performance or Stuck Off
P0752 .... Shift Solenoid 'A' Stuck On
P0753 .... Shift Solenoid 'A' Electrical
P0754 .... Shift Solenoid 'A' Intermittent
P0765 .... Shift Solenoid 'B'
P0756 .... Shift Solenoid 'B' Performance or Stuck Off
P0757 .... Shift Solenoid 'B' Stuck On
P0758 .... Shift Solenoid 'B' Electrical
P0759 .... Shift Solenoid 'B' Intermittent
P0760 .... Shift Solenoid 'C'
P0761 .... Shift Solenoid 'C' Performance or Stuck Off
P0762 .... Shift Solenoid 'C' Stuck On
P0763 .... Shift Solenoid 'C' Electrical
P0764 .... Shift Solenoid 'C' Intermittent
P0765 .... Shift Solenoid 'C'
P0766 .... Shift Solenoid 'D' Performance or Stuck Off
P0767 .... Shift Solenoid 'D' Stuck On
P0768 .... Shift Solenoid 'D' Electrical
P0769 .... Shift Solenoid 'D' Intermittent
P0770 .... Shift Solenoid 'E'
P0771 .... Shift Solenoid 'E' Performance or Stuck Off
P0772 .... Shift Solenoid 'E' Stuck On
P0773 .... Shift Solenoid 'E' Electrical

P0774 .... Shift Solenoid 'E' Intermittent
P0775 .... Pressure Control Solenoid 'B'
P0776 .... Pressure Control Solenoid 'B' Performance or Stuck Off
P0777 .... Pressure Control Solenoid 'B' Stuck On
P0778 .... Pressure Control Solenoid 'B' Electrical
P0779 .... Pressure Control Solenoid 'B' Intermittent
P0780 .... Shift
P0781 .... 1-2 Shift
P0782 .... 2-3 Shift
P0783 .... 3-4 Shift
P0784 ... .4-5 Shift
P0785 .... Shift/Timing Solenoid
P0786 .... Shift/Timing Solenoid Range/Performance
P0787 .... Shift/Timing Solenoid Low
P0788 .... Shift/Timing Solenoid High
P0789 .... Shift/Timing Solenoid Intermittent
P0790 .... Normal/Performance Switch Circuit
P0791 .... lntermediate Shaft Speed Sensor Circuit
P0792 .... lntermediate Shaft Speed Sensor Circuit Range/Performance
P0793 .... lntermediate Shaft Speed Sensor Circuit No Signal
P0794 .... lntermediate Shaft Speed Sensor Circuit Intermittent
P0795 .... Pressure Control Solenoid 'C'
P0796 .... Pressure Control Solenoid 'C' Performance or Stuck off
P0797 .... Pressure Control Solenoid 'C' Stuck On
P0798 .... Pressure Control Solenoid 'C' Electrical

P0799 .... Pressure Control Solenoid 'C' Intermittent
P0801 .... Reverse Inhibit Control Circuit
P0803 .... 1-4 Upshift (Skip Shift) Solenoid Control Circuit
P0804 .... 1-4 Upshift (Skip Shift) Lamp Control Circuit
P0805 .... Clutch Position Sensor Circuit
P0806 .... Clutch Position Sensor Circuit Range/Performance
P0807 .... Clutch Position Sensor Circuit Low
P0808 .... Clutch Position Sensor Circuit High
P0809 .... Clutch Position Sensor Circuit Intermittent
P0810 .... Clutch Position Control Error
P0811 .... Excessive Clutch Slippage
P0812 .... Reverse Input Circuit
P0813 .... Reverse Output Circuit
P0814 ... .Transmission Range Display Circuit
P0815 .... Upshift Switch Circuit
P0816 ... .Downshift Switch Circuit
P0817 .... Starter Disable Circuit
P0818 ... .Driveline Disconnect Switch Input Circuit
P0820 .... Gear Lever X-Y Position Sensor Circuit
P0821 .... Gear Lever X Position Circuit
P0822 .... Gear Lever Y Position Circuit
P0823 .... Gear Lever X Position Circuit Intermittent
P0824 .... Gear Lever Y Position Circuit Intermittent
P0825 .... Gear Lever Push-Pull Switch (Shift Anticipate)
P0830 .... Clutch Pedal Switch 'A' Circuit

P0831 .... Clutch Pedal Switch 'A' Circuit Low
P0832 .... Clutch Pedal Switch 'A' Circuit High
P0833 .... Clutch Pedal Switch 'B' Circuit
P0834 .... Clutch Pedal Switch 'B' Circuit Low
P0835 .... Clutch Pedal Switch 'B' Circuit High
P0836 .... Four Wheel Drive (4WD) Switch Circuit
P0837 .... Four Wheel Drive (4WD) Switch Circuit Range/Performance
P0838 .... Four Wheel Drive (4WD) Switch Circuit Low
P0839 .... Four Wheel Drive (4WD) Switch Circuit High
P0840 ... .Transmission Fluid Pressure Sensor/Switch 'A' Circuit
P0841 ... .Transmission Fluid Pressure Sensor/Switch 'A' Circuit Range/Performance
P0842 ... .Transmission Fluid Pressure Sensor/Switch 'A' Circuit Low
P0843 ... .Transmission Fluid Pressure Sensor/Switch 'A' Circuit High
P0844 ... .Transmission Fluid Pressure Sensor/Switch 'A' Circuit Intermittent
P0845 ... .Transmission Fluid Pressure Sensor/Switch 'B' Circuit
P0846 ... .Transmission Fluid Pressure Sensor/Switch 'B' Circuit Range/Performance
P0847 ... .Transmission Fluid Pressure Sensor/Switch 'B' Circuit Low
P0848 ... .Transmission Fluid Pressure Sensor/Switch 'B' Circuit High
P0849 ... .Transmission Fluid Pressure Sensor/Switch 'B' Circuit Intermittent
P0850 .... Park/Neutral Switch Input Circuit
P0851 .... Park/Neutral Switch Input Circuit Low
P0852 .... Park/Neutral Switch Input Circuit High
P0853 ... .Drive Switch Input Circuit
P0854 ... .Drive Switch Input Circuit Low
P0855 ... .Drive Switch Input Circuit High

P0856 ... .Traction Control Input Signal
P0857 ... .Traction Control Input Signal Range/Performance
P0858 ... .Traction Control Input Signal Low
P0859 ... .Traction Control Input Signal High
P0860 .... Gear Shift Module Communication Circuit
P0861 .... Gear Shift Module Communication Circuit Low
P0862 .... Gear Shift Module Communication Circuit High
P0863 ... .TCM Communication Circuit
P0864 ... .TCM Communication Circuit Range/Performance
P0865 ... .TCM Communication Circuit Low
P0866 ... .TCM Communication Circuit High
P0867 ... .Transmission Fluid Pressure
P0868 ... .Transmission Fluid Pressure Low
P0869 ... .Transmission Fluid Pressure High
P0870 ... .Transmission Fluid Pressure Sensor/Switch "C" circuit
P0871 ... .Transmission Fluid Pressure Sensor/Switch "C" Circuit Range/Performance
P0872 ... .Transmission Fluid Pressure Sensor/Switch "C" circuit Low
P0873 ... .Transmission Fluid Pressure Sensor/Switch "C" circuit High
P0874 ... .Transmission Fluid Pressure Sensor/Switch "C" circuit Intermittent
P0875 ... .Transmission Fluid Pressure Sensor/Switch "D" circuit
P0876 ... .Transmission Fluid Pressure Sensor/Switch "D" Circuit Range/Performance
P0877 ... .Transmission Fluid Pressure Sensor/Switch "D" circuit Low
P0878 ... .Transmission Fluid Pressure Sensor/Switch "D" circuit High
P0879 ... .Transmission Fluid Pressure Sensor/Switch "D" circuit Intermittent
P0880 ... .TCM Power Input Signal

P0881 ... .TCM Power Input Signal Range/Performance
P0882 ... .TCM Power Input Signal Low
P0883 ... .TCM Power Input Signal High
P0884 ... .TCM Power Input Signal Intermittent
P0885 ... .TCM Power Relay Control CircuiUOpen
P0886 ... .TCM Power Relay Control Circuit Low
P0887 ... .TCM Power Relay Control Circuit High
P0888 ... .TCM Power Relay Sense Circuit
P0889 ... .TCM Power Relay Sense Circuit Range/Performance
P0890 ... .TCM Power Relay Sense Circuit Low
P0891 ... .TCM Power Relay Sense Circuit High
P0892 ... .TCM Power Relay Sense Circuit Intermittent
P0893 .... Multiple Gears Engaged
P0894 ... .Transmission Component Slipping
P0895 .... Shift Time Too Short
P0896 .... Shift Time Too Long
P0897 ... .Transmission Fluid Deteriorated
P0898 ... .Transmission Control System MIL Request Circuit Low
P0899 ... .Transmission Control System MIL Request Circuit High
P0900 .... Clutch Actuator Circuit/Open
P0901 .... Clutch Actuator Circuit Range/Performance
P0902 .... Clutch Actuator Circuit Low
P0903 .... Clutch Actuator Circuit High
P0904 .... Gate Select Position Circuit
P0905 .... Gate Select Position Circuit Range/Performance

P0906 .... Gate Select Position Circuit Low
P0907 .... Gate Select Position Circuit High
P0908 .... Gate Select Position Circuit Intermittent
P0909 .... Gate Select Control Error
P0910 .... Gate Select Actuator CircuiUOpen
P0911 .... Gate Select Actuator Circuit Range/Performance
P0912 .... Gate Select Actuator Circuit Low
P0913 .... Gate Select Actuator Circuit High
P0914 .... Gear Shift Position Circuit
P0915 .... Gear Shift Position Circuit Range/Performance
P0916 .... Gear Shift Position Circuit Low
P0917 .... Gear Shift Position Circuit High
P0918 .... Gear Shift Position Circuit Intermittent
P0919 .... Gear Shift Position Control Error
P0920 .... Gear Shift Forward Actuator CircuiUOpen
P0921 .... Gear Shift Forward Actuator Circuit Range/Performance
P0922 .... Gear Shift Forward Actuator Circuit Low
P0923 .... Gear Shift Forward Actuator Circuit High
P0924 .... Gear Shift Reverse Actuator CircuiUOpen
P0925 .... Gear Shift Reverse Actuator Circuit Range/Performance
P0926 .... Gear Shift Reverse Actuator Circuit Low
P0927 .... Gear Shift Reverse Actuator Circuit High
P0928 .... Gear Shift Lock Solenoid Control Circuit/Open
P0929 .... Gear Shift Lock Solenoid Control Circuit Range/Performance
P0930 .... Gear Shift Lock Solenoid Control Circuit Low

P0931 .... Gear Shift Lock Solenoid Control Circuit High
P0932 .... Hydraulic Pressure Sensor Circuit
P0933 .... Hydraulic Pressure Sensor Range/Performance
P0934 .... Hydraulic Pressure Sensor Circuit Low
P0935 .... Hydraulic Pressure Sensor Circuit High
P0936 .... Hydraulic Pressure Sensor Circuit Intermittent
P0937 .... Hydraulic Oil Temperature Sensor Circuit
P0938 .... Hydraulic Oil Temperature Sensor Range/Performance
P0939 .... Hydraulic Oil Temperature Sensor Circuit Low
P0940 .... Hydraulic Oil Temperature Sensor Circuit High
P0941 .... Hydraulic Oil Temperature Sensor Circuit Intermittent
P0942 .... Hydraulic Pressure Unit
P0943 .... Hydraulic Pressure Unit Cycling Period Too Short
P0944 .... Hydraulic Pressure Unit Loss of Pressure
P0945 .... Hydraulic Pump Relay Circuit/Open
P0946 .... Hydraulic Pump Relay Circuit Range/Performance
P0947 .... Hydraulic Pump Relay Circuit Low
P0948 .... Hydraulic Pump Relay Circuit High
P0949 .... Auto Shift Manual Adaptive Learning Not Complete
P0950 .... Auto Shift Manual Control Circuit
P0951 .... Auto Shift Manual Control Circuit Range/Performance
P0952 .... Auto Shift Manual Control Circuit Low
P0953 .... Auto Shift Manual Control Circuit High
P0954 .... Auto Shift Manual Control Circuit Intermittent
P0955 .... Auto Shift Manual Mode Circuit

P0956 .... Auto Shift Manual Mode Circuit Range/Performance
P0957 .... Auto Shift Manual Mode Circuit Low
P0958 .... Auto Shift Manual Mode Circuit High
P0959 .... Auto Shift Manual Mode Circuit Intermittent
P0960 .... Pressure Control Solenoid "A" Control Circuit/Open
P0961 .... Pressure Control Solenoid "A" Control Circuit Range/Performance
P0962 .... Pressure Control Solenoid "A" Control Circuit Low
P0963 .... Pressure Control Solenoid "A" Control Circuit High
P0964 .... Pressure Control Solenoid "B" Control Circuit/Open
P0965 .... Pressure Control Solenoid "B" Control Circuit Range/Performance
P0966 .... Pressure Control Solenoid "B" Control Circuit Low
P0967 .... Pressure Control Solenoid "B" Control Circuit High
P0968 .... Pressure Control Solenoid "C" Control Circuit/Open
P0969 .... Pressure Control Solenoid "C" Control Circuit Range/Performance
P0970 .... Pressure Control Solenoid "C" Control Circuit Low
P0971 .... Pressure Control Solenoid "C" Control Circuit High
P0972 .... Shift Solenoid "A" Control Circuit Range/Performance
P0973 .... Shift Solenoid "A" Control Circuit Low
P0974 .... Shift Solenoid "A" Control Circuit High
P0975 .... Shift Solenoid "B" Control Circuit Range/Performance
P0976 .... Shift Solenoid "B" Control Circuit Low
P0977 .... Shift Solenoid "B" Control Circuit High
P0978 .... Shift Solenoid "C" Control Circuit Range/Performance
P0979 .... Shift Solenoid "C" Control Circuit Low
P0980 .... Shift Solenoid "C" Control Circuit High

P0981 .... Shift Solenoid "D" Control Circuit Range/Performance
P0982 .... Shift Solenoid "D" Control Circuit Low
P0983 .... Shift Solenoid "D" Control Circuit High
P0984 .... Shift Solenoid "E" Control Circuit Range/Performance
P0985 .... Shift Solenoid "E" Control Circuit Low
P0986 .... Shift Solenoid "E" Control Circuit High
P0987 ... .Transmission Fluid Pressure Sensor/Switch "E" Circuit
P0988 ... .Transmission Fluid Pressure Sensor/Switch "E" Circuit Range/Performance
P0989 ... .Transmission Fluid Pressure Sensor/Switch "E" Circuit Low
P0990 ... .Transmission Fluid Pressure Sensor/Switch "E" Circuit High
P0991 ... .Transmission Fluid Pressure Sensor/Switch "E" Circuit Intermittent
P0992 ... .Transmission Fluid Pressure Sensor/Switch "F" Circuit
P0993 ... .Transmission Fluid Pressure Sensor/Switch "F" Circuit Range/Performance
P0994 ... .Transmission Fluid Pressure Sensor/Switch "F" Circuit Low
P0995 ... .Transmission Fluid Pressure Sensor/Switch "F" Circuit High
P0996 ... .Transmission Fluid Pressure Sensor/Switch "F" Circuit Intermittent
P0997 .... Shift Solenoid "F" Control Circuit Range/Performance
P0998 .... Shift Solenoid "F" Control Circuit Low
GM CODES
GM Code List P1OOO-P1299
NOTE: For some code numbers, there may be more than one definition because the same number may
be used for different faults on different model years or models.
P1031 .... 02 Sensor heater control circuit problem
P1105 .... Secondary Vacuum Sensor circuit
P1106 .... MAP sensor circuit voltage intermittent high or low
P1107 .... MAP sensor voltage intermittent low
P1108 .... BARO to MAP sensor circuit comparison too high
P1109 .... Secondary port throttle system
P1111 .... lntake Air Temperature Sensor circuit intermittent high voltage
P1112 .... lntake Air Temperature Sensor circuit intermittent low voltage
P1113 .... lntake Resonance Switchover Valve Control
P1114 .... Engine Coolant Temperature intermittent high or low
P1115 .... Engine Coolant Temperature intermittent high or low
P1116 .... Engine Coolant Temperature erratic
P1117 .... Engine coolant temperature below minimum voltage/254 F
P1118 .... Engine coolant temperature above maximum voltage/-40 F
P1119 .... Engine coolant temperature out of range
P1120 ... .Throttle position sensor 1 circuit
P1121 .... lgnition control module 4X circuit, or TPS out of range
P1122 .... lgnition control module 4X circuit, or TPS out of range
P1125 .... Average Pump Period system, or pedal position system
P1133 .... A/C pressure sensor high voltage, or 02 sensor bank 1 sensor 1 sluggish
P1134 .... 5 volt reference 2 voltage low, or 02 sensor bank 1 sensor 1
P1135 .... 02 Sensor 1 bank 1 reading lean, or 4/5 shift solenoid stuck on
P1136 .... 5 volt reference 2 circuit, or 02 sensor bank 1 sensor 1 rich
P1137 .... 02 Sensor low voltage during power enrichment
P1138 .... 02 Sensor high voltage during decel fuel cutoff
P1139 .... Brake booster vacuum sensor (low vacuum)
P1139 .. 02 Sensor insufficient switching (Bank 1 Sensor 2)
P1140 .... 02 Sensor Sluggish (Bank 1 Sensor 2)
P1141 .... 02 Sensor Heater Control circuit (Bank 1 Sensor 2)
P1143 .... 02 Sensor reading lean or low voltage (Bank 1 Sensor 3)
P1144 .... 02 Sensor reading rich or high voltage (Bank 1 Sensor 3)
P1145 .... 02 Sensor sluggish (slow crosscounts) (Bank 1 Sensor 3)
P1153 .... A/C pressure sensor low voltage
P1153 ..... 02 Sensor low switching (Bank 2 Sensor 1)
P1154 .... 02 Sensor low transition time (Bank 2 Sensor 1)
P1155 .... A/C evap temperature switch high voltage
P1155 .. 02 Sensor reading lean (Bank 2Sensor1)
P1156 .... A/C high pressure switch high voltage
P1156 .. 02 Sensor reading rich (Bank 2Sensor1)
P1157 .... 02 Sensor rich or high voltage (Bank 2 Sensor 2)
P1158 .... 02 Sensor rich or high voltage (Bank 2 Sensor 2)
P1158 ... Engine overtemperature protection fault
P1159 .... 02 Sensor crosscounts (Bank 2 Sensor 2)
P1161 .... 02 Sensor heater control circuit (Bank 2 Sensor 2)
P1163 .... 02 Sensor reading lean or low voltage (Bank 2 Sensor 3)
P1164 .... 02 Sensor reading rich or high voltage (Bank 2 Sensor 3)
P1165 .... 02 Sensor crosscounts (Bank 2 Sensor 3)

P1170 .... Bank to bank fuel trim offset
P1171 .... Fuel system lean during acceleration
P1185 .... Engine Temperature Sensor circuit
P1186 .... Engine Oil Temperature circuit performance
P1187 .... Engine Oil Pressure Sensor circuit low voltage,
P1188 .... Engine Oil Pressure Sensor circuit voltage high
P1189 .... Engine Oil Pressure Switch circuit
P1190 ... .Vacuum leak
P1191 .... lntake air duct leak
P1200 .... lnjector control circuit
P1211 .... Mass Airflow circuit intermittent high
P1212 .... Mass Airflow circuit intermittent low
P1214 .... lnjection Pump Timing Offset
P1215 .... Ground fault detection indicated (generator driver circuit)
P1216 .... Fuel Solenoid response time too short
P1217 .... Fuel Solenoid response time too long
P1218 .... lnjection Pump calibration circuit
P1219 ... .Throttle Position Sensor reference voltage
P1220 ... .Throttle Position Sensor circuit fault
P1221 .... Fuel pump second circuit low
P1121 .. Throttle position sensor circuit performance
P1222 .... lnjector circuit cylinder 1 intermittent

P1237 .... Injector circuit cylinder 6 intermittent
P1250 .... Early fuel evaporation heater circuit
P1257 .... Boost Control fault, or supercharger overboost
P1258 .... Engine overtemperature protection, or low coolant fuel disable
P1260 .... Fuel Pump Speed Relay control circuit, or last test failed speed control circuit
P1271 .... Accelerator Pedal Position Sensor 1-2 correlation
P1272 .... Accelerator Pedal Postion Sensor 2-3 correlation
P1273 .... Accelerator Pedal Position Sensor 1-3 correlation
P1274 .... lnjection wiring incorrect
P1275 .... Acceleration position sensor 2 circuit, or boost control
P1276 .... Accelerator Pedal Positioning Sensor 1 circuit
P1281 .... Accelerator Pedal Positioning Sensor 2 circuit out of range
P1286 .... Accelerator Pedal Positioning Sensor 2 circuit out of range
GM Code List P1300-P1499
P1300 .... lgnition coil 1 primary feedback circuit
P1305 .... lgnition Coil 2 primary feedback circuit
P1320 ... .Distributorless ignition 4X signal intermittent

P1321 .... Electronic ignition system fault
P1322 .... Electronic ignition system control missing
P1323 .... Loss of high resolution rpm signal
P1324 .... Crank rpm too low
P1335 .... Crankshaft positioning sensing circuit
P1336 .... Crankshaft position system variation not learned
P1345 .... Camshaft to crankshaft position correlation fault
P1346 .... Crankshaft sensor system variation not learned, or intake camshaft position out of range
P1349 .... lntake Camshaft position system
P1350 .... lgnition control system
P1351 .... lgnition controlcircuit voltage high
P1351 .... lgnition control circuit open
P1352 .... Bypass circuit open or voltage high
P1353 .... lgnition control output high/pulse detected when ground cylinder #3
P1357 .... Ignition control output high/pulse detected when ground cylinder #7
P1359 .... lgnition Coil group 1 control circuit
P1360 .... lgnitiion Coil group 2 control circuit
P1361 .... lgnition control cylinder #1 not toggling after enable,or low voltage
P1362 .... lgnition control cylinder #2 not toggling after enable,or low voltage, or bypass circuit shorted or
low voltage
P1367 .... Ignition control cylinder #7 not toggling after enable,or low voltage
P1368 .... lgnition control cylinder #8 not toggling after enable, or low voltage
P1370 ... .Too many ignition reference pulses
P1371 ... .Too few ignition reference pulses
P1372 .... Crankshaft Position Sensor A-B correlation
P1374 .... Crankshaft position sensor, 3X Reference circuit
P1375 .... 24X Reference circuit voltage too high
P1376 .... Reference voltage low, or ignition ground circuit
P1377 .... Ignition control module CAM pulse to 4X reference pulse comparison
P1380 .... ABS rough road/misfire diagnosis prevented
P1381 .... Misfire detected, no EBCM/PCM serial data
P1401 .... Exhaust Gas Recirculation flow test fault
P1403 .... Exhaust Gas Recirculation Solenoid 1 error
P1404 .... Exhaust Gas Recirculation Solenoid 2 error
P1405 .... Exhaust Gas Rrecirculation Solenoid 3 error
P1406 .... Exhaust Gas Recirculation pintle position error
P1407 .... EGR valve air leak
P1408 .... EGR valve vacuum failure
P1409 .... EGR valve vacuum leak
P1410 .... EGR valve vacuum restriction, or fuel tank pressure system
P1415 .... AIR system Bank 1
P1416 .... AIR system Bank 2
P1431 .... Fuel Level Sensor 2 circuit

P1432 .... Fuel Level Sensor 2 circuit low voltage
P1433 .... Fuel Level Sensor 2 circuit voltage high
P1441 .... EVAP Canister continuous open purge flow,or high voltage during non-purge
P1442 .... EVAP monitor circuit/vacuum switch high voltage
P1450 .... Barometric Pressure Sensor (BARO) circuit
P1451 .... Barometric Pressure Sensor performance
P1460 .... Cooling Fan control system, or misfire detected (Catera only)
P1483 .... Engine cooling system performance
P1500 .... Starter signal circuit
P1501 ... .Vehicle speed sensor circuit intermittent, or Theft deterrent system
P1502 ... .Theft deterrent system no password received
P1503 ... .Theft deterrent system password improper
P1508 .... ldle Air Control system -- idle too low
P1509 .... ldle Air Control system -- idle too high
P1510 .... Backup power supply
P1511 ... .Throttle Control System - backup system performance
P1514 .... Airflow to throttle position sensor too high
P1515 .... Electronic throttle module throttle position
P1516 .... Electronic throttle module throttle postion
P1517 .... Electronic throttle module, or TAC module fault
P1518 .... No communication between electronic throttle module and PCM
P1519 ... .Throttle Actuator Control Module
P1520 .... Park/Neutral Switch circuit, gear indicator system

P1523 .... Electronic throttle control throttle return
P1524 ... .Throttle Position Sensor out of range or misadjusted
P1525 ... .Throttle Body Service required
P1526 ... .Throttle position learn process not complete
P1527 ... .Transmission range/pressure switch comparison
P1528 .... Governor control system
P1530 .... lgnition timing adjustment switch circuit, or A/C Refrigerant Pressure Sensor error
P1531 .... A/C low refrigerant
P1532 .... Engine coolant temperature sensor intermittent, or A/C Evaporator Temperature circuit low
voltage
P1533 .... A/C Low Side Temperature Sensor circuit
P1535 .... A/C High Side Temperature Sensor circuit
P1536 .... A/C system ECT overtemperature
P1537 .... A/C request circuit voltage low
P1538 .... A/C request circuit voltage high
P1539 .... A/C High Pressure Switch circuit voltage high
P1540 .... A/C system high pressure
P1542 .... A/C system high pressure or high temperature
P1543 ... A/C system performance out of range
P1545 .... A/C Clutch Relay Control circuit
P1546 .... A/C Clutch Relay control circuit voltage low
P1550 .... Cruise control, motor actuator circuit
P1554 .... Speed Control status circuit
P1555 .... Elecrtric Variable Orifice fault (Saturn)
P1558 .... Speed Control (SPS low)
P1560 .... Speed Control System!Transaxle not in Drive

P1561 .... Speed Control Vent Solenoid
P1562 .... Speed Control Vacuum Solenoid
P1564 .... ECM battery voltage loss (Catera only), or speed control system/vehicle acceleration too high
P1565 .... Speed Control Servo Position Sensor
P1566 .... Speed Control System/Engine RPM too high
P1567 .... Speed Control Master Switch
P1568 .... Speed Control (SPS high)
P1570 .... Speed Control System!Traction Control active
P1571 ... .Traction Control System desired torque circuit
P1572 ... .Traction Control System active circuit voltage low too long
P1573 .... PCM/EBTCM serial data circuit communication malfunction
P1574 .... EBTCM system/stop lamp circuit voltage high
P1575 .... Stop lamp control circuit (97-98 Corvette only), or extended travel brake switch circuit voltage
high
P1576 .... Brake Booster Vacuum Sensor circuit voltage high
P1577 .... Brake Booster Vacuum Sensor circuit voltage low
P1578 .... Brake Booster Vacuum Sensor circuit low vacuum
P1579 .... Park/Neutral to Drive/Reverse at high throttle angle
P1580 .... Cruise Control Module move circuit, low voltage
P1581 .... Cruise Control Module move circuit, high voltage
P1582 .... Cruise Control Module direction circuit, low voltage
P1583 .... Cruise Control Module direction circuit, high voltage
P1584 .... Cruise control disabled
P1585 .... Cruise Control inhibit output circuit
P1586 .... Cruise Control Brake Switch 2 circuit
P1599 .... Engine stall detected

P1600 .... Powertrain control module battery, or loss of communication between PCM and TCM
P1601 .... ECM overtemperature
P1602 .... PCM to ABS module communication problem
P1603 .... Serial data communicatiion problem
P1604 .... IPC Serial data communication problem
P1605 .... Serial data communication problem with HVAC module
P1607 .... Engine Oil Level Switch circuit
P161 O.... Loss of PZM serial data, or failure of body function controller (1997 Cutlass & Malibu only)
P1611 .... Loss of CVRTD serial data
P1617 .... Engine Oil Level Switch circuit
P1619 .... Engine Oil Life Monitor reset circuit, or oil life error
P1620 .... Engine coolant low (Saturn)
P1621 .... Powertrain control module memory error, or VCM EE PROM performance (1998 5.7L only)
P1623 .... PCM Prom error, or Transaxle Temperature Sensor fault (Saturn)
P1624 .... Powertrain conrol module software reset, or customer snapshot data avaialable (Saturn)
P1625 .... Powertrain control module system reset, or TCM flash checksum fault (Saturn)
P1626 .... Anti-theft system fuel enable circuit (Passkey error)
P1627 .... AID performance, or Powertrain Control Module fault
P1628 .... PCM Engine Control Temperature Pull-up Resistor, or Engine Coolant Temperature Sensor
circuit resistor fault
P1629 .... Anti-theft devide cranking signal or Passkey cranking error
P1630 .... System voltage too high/too low, or ECM immobilizer learning mode (Cavalier & Monte Carlo
only)
P1631 .... 0xygen sensor #1 slow response, or anti-theft password incorrect
P1632 .... Anti-theft fuel disable signal received
P1633 .... lgnition power circuit low voltage
P1634 .... lgnition power circuit low voltage

P1635 .... 5 volt reference voltage to sensors low
P1636 .... Powertrain control module fault
P1637 .... Alternator warning lamp control signal "L" terminal problem
P1638 .... Alternator Field (F) terminal circuit
P1639 .... Powertrain Control Module 5 volt reference voltage low
P1641 .... EVAP fuel tank pressure sensor circuit voltage high, or fan 1 relay control circuit, or MIL light
circuit, or A/C compressor clutch relay circuit
P1642 .... Fan control relay, or vehicle speed sensor output, or secondary air injection relay fault (96
Lumina/Monte 3.4L)
P1644 ... .Throttle position sensor circuit, or traction control fault
P1645 .... Boost control solenoid circuit, or EVAP solenoid output circuit
P1646 .... Powertrain control module fault (quad driver 1)
P1651 .... Powertrain control module fault (quad driver 2), or cooling fan relay 1
P1652 .... Cooling fan relay 2, or suspension control module (Cadillac only)
P1653 ... .Traction control circuit (Pontiac), or fuel gauge control circuit (Chevy except Caprice), or engine
oil level warning lamp (Caprice & 99 Olds Silhouette only)
P1654 .... A/C relay circuit, or cruise control disable output circuit
P1655 .... Powertrain control module fault (quad driver 2), or EVAP canister purge valve
P1656 .... Powertrain control module fault (quad driver 2), or wastegate solenodi control circuit (turbo
models only)
P1657 .... Powertrain control module fault (quad driver 2), or skip shift solenodi control circuit
P1660 .... Cooling fan circuit,or powertrain control module fault
P1661 .... EVAP fuel tank pressure sensor circuit, or Check Engine Light circuit, or PCM quad driver fault
P1662 .... PCM quad driver fault, or cruise control circuit

P1663 .... Alternator warning lamp circuit, or oil change warning lamp circuit
P1664 .... Powertrain control modeul fault (quad driver 3), or fuel cutoff solenoid
P1665 .... Powertrain control module fault (quad driver 3), or EVAP canister vent valve
P1667 .... Powertrain control module fault (quad driver 3), or reverse inhibit solenoid control circuit
P1671 .... Malfunction Indicator Lamp (MIL) circuit fault
P1672 .... Powertrain control module fault (quad driver 4), or low engine oil level lamp control circuit
P1673 .... Powertrain control module fault (quad driver 4), or engine hot lamp control circuit
P1674 .... Powertrain control module fault (quad driver 4), or tachometer control circuit
P1675 .... EVAP vent solenoid controlcircuit
P1676 .... Powertrain control module fault (quad driver 4), or EVAP canister vent valve
P1689 ... .Traction Control System delivered torque control circuit
P1690 .... Powertrain control module loop overrun
P1691 .... Coolant gauge circuit voltage low
P1692 .... Coolant gauge circuit voltage high
P1693 ... .Tachometer circuit voltage low

P1694 ... .Tachometer circuit voltage high
P1695 .... Remote keyless entry circuit
P1696 .... Remote keyless entry circuit
P1700 .... Malfunction Indicator Lamp requested by trans control module
P1701 .... Malfunction Indicator Lamp request circuit
P17 40 ... .Torque control/management request circuit
P1760 ... .Transmission Control Module supply voltage interrupted
P1780 .... Park/Neutral Position Switch circuit
P1781 .... Engine torque signal circuit
P1792 .... ECM to Transmission Control Module engine coolant signal
P1800 .... ECM to Transmission Control Module engine coolant signal
P1810 .... ATF pressure manual valve powition switch malfunction
P1811 .... Long shift and maximum adaptation limit reached
P1812 ... .TOT condition
P1814 ... .Torque converter clutch (TCC) overstress
P1819 ... .Transmission range switch out of range, possible no start
P1820 ... .Transmission range switch A voltage low
P1822 ... .Transmission range switch B voltage high
P1823 ... .Transmission range switch P voltage low
P1825 ... .Transmission range switch A, B, C & P signals invalid
P1826 ... .Transmission range switch C voltage high
P1835 .... Kickdown Switch circuit
P1842 .... 1-2 Shift Solenoid circuit low input

P1843 .... 1-2 Shift Solenoid circuit high input
P1845 .... 2-3 Shift Solenoid circuit low input
P1847 .... 2-3Shift Solenoid circuit high input
P1850 .... Brake Band Aply Solenoid
P1860 ... .Torque Converter Clutch (TCC) PWM Solenoid circuit
P1864 ... .TCC Enable Solenoid circuit
P1868 ... .Transmission Fluid life
P1870 ... .Transmission component slipping
P1873 .... 0xygen sensor bank 2 sensor 2 crosscounts
P1874 .... 0xygen sensor bank 1sensor3 crosscounts
P1875 ... .4WD Low Switch circuit electrical
P1886 ... .Transaxle Shift, Timing Solenoid performance
P1887 ... .TCC Release Switch malfunction
P1890 ... .Throttle Position signal input
P1891 ... .Throttle position sensor circuit signal low
P1892 ... .Throttle position sensor circuit signal high
P1895 .... Engine torque delivered circuit
Document ID: 299659
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories | Horns |

Specification
Application
Metric
English
Backup Lamp to Rear Compartment Lid
9 Nm
80 lb in
Daytime Running Lamp Resistor to Body
7 Nm
62 lb in
Headlamp Bracket to Body
9 Nm
80 lb in
15 Nm
11 lb ft
9 Nm
80 lb in
Horns to Body
Taillamp to Quarter
2/7/2011
Document ID: 346929
Page 1 of 1
Horn Schematics
Cell 40: Horns
2/7/2011
Document ID: 343057
Page 1 of 1
Front of the Engine Compartment
(1) LH Horn F Note

(2) RH Horn A Note
2/7/2011
Document ID: 343260
Page 1 of 1

(7) Horn Relay
2/7/2011
Document ID: 415161
Page 1 of 2
Horn Connector End Views

Table 1:
LH Horn
Table 2:
RH Horn
LH Horn
12052638
2 Way F Metri-Pak 150 Series (LT GRA)
Pin
Wire Color
Circuit No.
BLK
1150
DK GRN
29
Function
Ground
Horn Feed
RH Horn

Pin
Wire Color
12052638
2-Way F Metri-Pack 150 Series (LT GRA)
Circuit No.
Function
2/7/2011
Document ID: 415161
Page 2 of 2
BLK
1550
DK GRN
29
Ground
Horn Feed
2/7/2011
Document ID: 401090
Page 1 of 2
Horn Replacement (A Note)

Removal Procedure
1.
2.
3.
4.
Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
Remove the horn stud from the right front fender.
Remove the horn.
Disconnect the connector from the horn.
2/7/2011
Document ID: 401090
Page 2 of 2
1. Install the horn connector to the horn.

2. Install the horn to the front fender.
3. Install the horn stud to the front fender.
Tighten
Tighten the horn stud to 15 Nm (11 lb ft).
4. Install the coolant recovery container. Refer to Coolant Recovery Reservoir Replacement .
2/7/2011
Document ID: 401091
Page 1 of 2
Horn Replacement (F Note)

Removal Procedure
1. Remove the air cleaner assembly.
2. Remove the PCM.
3. Remove the horn bolt from the left front fender.

4. Remove the horn.
5. Disconnect the connector from the horn.
2/7/2011
Document ID: 401091
Page 2 of 2
1. Connect the horn connector to the horn.

2. Install the horn to the front fender.
3. Install the horn bolt to the front fender.
Tighten
Tighten the horn bolt to 15 Nm (11 lb ft).
2/7/2011
Document ID: 297263
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | HVAC |

HVAC Systems - Automatic | Specifications | Document ID: 297263
1999 Oldsmobile Eighty Eight

Specification
Application
Metric
English
Accumulator Retaining Bolt
6 Nm
53 lb in
Air Inlet Retaining Screws
5 Nm
44 lb in
Air Mix Valve Actuator Screws
1.4 Nm
12 lb in
Ambient Air Temperature Sensor Bolt
12 Nm
106 lb in
A/C Compressor Hose Assembly Bolt
30 Nm
22 lb ft
A/C Module Cover Retaining Screws
3 Nm
27 lb in
Compressor Mounting Bracket Rear Bolt
50 Nm
37 lb ft
Compressor Mounting Bracket Side Bolts
100 Nm
74 lb ft
Condenser Mounting Brackets
12 Nm
106 lb in
Front Compressor Mounting Nuts
50 Nm
37 lb ft
Heater and A/C Programmer Screws
1.4 Nm
12 lb in
Heater Core Cover Screws
1.4 Nm
12 lb in
Inside Air Temperature Sensor Screws
1.4 Nm
12 lb in
Rear Compressor Mounting Bolt
50 Nm
37 lb ft
Service Fitting
12 Nm
9 lb in
Tighten All Dual O-ring Fittings
24 Nm
18 lb ft
tomsn048@gmail.com
http://localhost:9001/si/showDoc.do?docSyskey=297263&pubCellSyskey=48569&pubO... 10/22/2010
Document ID: 341938
Page 1 of 1

HVAC Systems - Automatic | Schematic and Routing Diagrams | Document ID: 341938
Cell 68: Heater and A/C Programmer -- Buick
tomsn048@gmail.com
10/22/2010
Document ID: 341942
Page 1 of 1

Cell 68: IP Fuse Block, Heater and A/C Control Assembly -Buick
tomsn048@gmail.com
10/22/2010
Document ID: 341944
Page 1 of 1

Cell 68: Passenger Temperature Control -- Buick
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10/22/2010
Document ID: 341960
Page 1 of 1

Cell 68: Vacuum Tank -- Oldsmobile, Buick
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10/22/2010
Document ID: 341963
Page 1 of 1

Cell 68: Passenger Air Mix Actuator -- Oldsmobile, Buick
tomsn048@gmail.com
10/22/2010
Document ID: 341867
Page 1 of 1

HVAC Systems - Manual | Schematic and Routing Diagrams | Document ID: 341867
HVAC Air Delivery Schematics (Cell 65: A/C Mode Selector -Buick)
tomsn048@gmail.com
10/22/2010
Document ID: 341857
Page 1 of 1

Cell 65: Fuse Box, Actuator -- Buick
tomsn048@gmail.com
10/22/2010
Document ID: 341840
Page 1 of 1

Cell 63: Buick
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10/22/2010
Document ID: 297265
Page 1 of 1

HVAC Blower Control Schematics

HVAC Blower Control Schematics (Cell 66)
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Document ID: 341851
Page 1 of 1

Cell 64: Buick
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10/22/2010
Document ID: 297266
Page 1 of 1

HVAC Compressor Control Schematics

HVAC Compressor Control Schematics (Cell 67)
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Document ID: 297068
Page 1 of 1

System Capacities
Specification
Application
Refrigerant Capacity
tomsn048@gmail.com
Metric
English
0.91 kg
2.0 lb
Document ID: 297070
Page 1 of 1

Refrigerant Oil Distribution Specifications

Specification
Application
Metric
English
Accumulator
90 ml
3 oz
Compressor
60 ml
2 oz
Condenser
30 ml
1 oz
Evaporator
90 ml
3 oz
tomsn048@gmail.com
Document ID: 343041
Page 1 of 1

HVAC Systems - Automatic | Component Locator | Document ID: 343041
Center Front of the Vehicle
(1) Ambient Air Temperature Sensor
tomsn048@gmail.com
10/22/2010
Document ID: 343257
Page 1 of 1

Engine Compartment, Rear
(1) Blower Motor

(2) P101
(3) C101
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10/22/2010
Document ID: 343258
Page 1 of 1

Engine Compartment, Right Rear Corner
(1) S104
(2) Blower Motor
(3) Blower Motor Resistor, Blower Control Module (Hidden)
(4) Blower Control Module
(5) Blower Motor Resistor
(6) S101
(7) S103
(8) S102
tomsn048@gmail.com
10/22/2010
Document ID: 343260
Page 1 of 1


(7) Horn Relay
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10/22/2010
Document ID: 343268
Page 1 of 1

Engine, Front Side
(1) Knock Sensor Bank 1

(2) Starter Solenoid
(3) Engine Oil Level Switch
(4) A/C Pressure Sensor
(5) A/C Clutch
(6) A/C Clutch Diode
(7) S107
(8) S106
tomsn048@gmail.com
10/22/2010
Document ID: 343328
Page 1 of 1

Passenger Compartment, Under the Steering Column
(1) Inside Air Temperature Sensor

(2) Traction Control Disable Switch (Buick)
(3) Rear Compartment Lid Release Switch (Pontiac)
(4) LH Knee Bolster
(5) Interior Lamp Control Module
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10/22/2010
Document ID: 400526
Page 1 of 1


Others Similar

(2) Cigar Lighter
(5) Radio
(7) Fog Lamp Switch
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10/22/2010
Document ID: 343365
Page 1 of 1

(1) S240
(2) S269
(3) S268
(4) Heater and A/C Programmer
tomsn048@gmail.com
10/22/2010
Document ID: 343319
Page 1 of 2

Passenger Compartment, Behind the Instrument Panel

(Oldsmobile)
(1) LH Sunload Temperature Sensor

(2) Twilight Sentinel
(3) Headlamp Switch Connector
(4) Traction Control Disable Switch
(5) Interior Lamp Control Module
(6) Ambient Air Temperature Sensor
(7) C200
(8) C304
(9) Valet Switch
(10) S209
(11) S249
(12) S216
(13) Radio
(14) C207
(15 ) RH Sun Load Temperature Sensor
(16) IP Compartment Switch
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(17) S214
10/22/2010
Document ID: 343319
Page 2 of 2
(18) S213
(19) S291
(20) S264
(21) S260
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10/22/2010
Document ID: 359495
Page 1 of 12

HVAC Connector End Views

Table 1:
A/C Clutch
Table 2:
A/C Clutch Relay
Table 3:
A/C Pressure Sensor
Table 4:
Blower Control Module C1
Table 5:
Table 6:
Heater and A/C Control (Buick / Oldsmobile with CJ2)
Table 7:
Heater and A/C Control (Pontiac With C68)
Table 8:
Heater and A/C Programmer (Pontiac)
Table 9:
Heater and A/C Programmer (Buick with CJ2)
Table 10: Heater and A/C Programmer (Oldsmobile with CJ2)

Table 11: Inside Air Temperature Sensor
Table 12: LH Sunload Temperature Sensor (Buick)
Table 13: LH Sunload Temperature Sensor (Oldsmobile)
Table 14: Passenger Temperature Control (Buick with CJ2)
Table 15: Passenger Temperature Control (Oldsmobile with CJ2)
Table 16: RH Sunload Temperature Sensor (Buick)
Table 17: RH Sunload Temperature Sensor (Oldsmobile)
Table 18: Sunload Temperature Sensor (Pontiac)
A/C Clutch
12162017
Pin
Wire Color
Circuit No.
DK GRN
59
BLK
1450
Function
A/C Compressor Clutch Solenoid Feed
Ground
A/C Clutch Relay

tomsn048@gmail.com
Document ID: 359495
Connector Part
Information
Page 2 of 12
12110787
Pin
Wire Color
Circuit
No.
30
PNK
239
Fused Output - Ignition 1
85
DK GRN/WHT
459
Air Conditioning Compressor Control Relay Output Ignition 1
86
PNK
239
87
DK GRN
59
Function
Air Conditioning Compressor Clutch Solenoid Feed
A/C Pressure Sensor
12110192
Pin
Wire Color
Circuit No.
BLK
808
Sensor Return
GRY/BLK
474
5 Volt Reference Feed
RED/BLK
380
A/C Refrigerant Pressure Sensor Signal
Function
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Document ID: 359495
Page 3 of 12
12059405
Pin
Wire Color
Circuit No.
--
--
RED
442
Function
Not Used
Connector Part
Information
12059407
Pin
Wire Color
Circuit
No.
PPL
65
GRY/BLK
754
Blower Speed Signal - Speed Control (Pontiac)
GRY/BLK
754
Blower Speed Signal - Speed Control

(Oldsmobile)
GRY/BLK
754
Blower Speed Signal - Speed Control (Buick)
BLK
1550
Function
Blower Motor Feed
Ground
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Document ID: 359495
Page 4 of 12
--
Not Used
--
Heater and A/C Control (Buick / Oldsmobile with CJ2)
12110259
16-Way F Micro-Pack 100 Series (GRN)
Pin
Wire Color
Circuit No.
A1-A6
--
--
A7
BRN
1141
Fused Output - Ignition
A8
BLK
1250
Ground
B1
LT BLU
1880
HVAC Control Assembly Signal - Driver
B2
PPL
1881
HVAC Control Assembly Signal - Clock - Driver
B3
GRY
B4-B7
--
--
Not Used
B8
BLK
1250
Function
Not Used
Ground (Oldsmobile)
Heater and A/C Control (Pontiac With C68)
tomsn048@gmail.com
12004702
Printed Circuit Component (BLK)
Document ID: 359495
Page 5 of 12
Pin
Wire Color
Circuit No.
GRY
I/P Lamp Feed
2-3
--
--
Not Used
DK GRN
835
DK GRN
835
6-8
--
--
BLK
1250
10
YEL
32
11
BRN
1141
12
--
--
Not Used
A-H
--
--
Not Used
J-M
--
--
Not Used
Function
Not Used
Ground
Fused Output - I/P Lamps
Heater and A/C Programmer (Pontiac)
12045469
32-Way F Micro-Pack 100 Series (RED)
Pin
Wire Color
Circuit No.
C1
BLK/WHT
251
C2-C4
--
--
C5
DK GRN
835
C6
BLK
1450
C7
DK GRN
835
C8
--
--
C9
GRY/BLK
754
C10
TAN
800
C11
TAN
800
C12
BRN
1141
C13
ORN
40
C14-C16
--
--
Not Used
tomsn048@gmail.com
Function
Ground-Clean
Not Used
Ground
Not Used
Document ID: 359495
Page 6 of 12
Not Used
D1
--
--
D2
ORN
761
D3
--
--
D4
DK GRN/ WHT
762
A/C Request Signal
D5
WHT
193
Rear Defogger Relay Output - Coil
D6
BLK/WHT
1704
D7
DK GRN
734
Inside Temperature Sensor Signal
D8
LT GRN/BLK
735
Outside Ambient Temperature Sensor Signal
D9
--
--
D10
LT BLU/BLK
590
D11-D16
--
--
Blower Speed Signal - Speed Feedback

Not Used
Sensor Return
Not Used
Solar Sensor Signal - Driver
Not Used
Heater and A/C Programmer (Buick with CJ2)
Connector Part
Information
12052107
32 Way F Micro-Pack 100 Series (ORN)
Pin
Wire Color
Circuit
No.
E1
BLK/WHT
251
E2-E4
--
--
E5
DK GRN
835
E6
BLK
1450
E7
DK GRN
835
E8
--
--
E9
GRY/BLK
754
E10
TAN
800
E11
TAN
800
E12
BRN
1141
E13
ORN
40
E14
PPL/WHT
724
Function
Ground
Not Used
Ground
Not Used
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Document ID: 359495
Page 7 of 12
E15
GRY
1548
Passenger Solar Sensor Signal
E16
LT BLU
1880
F1
--
--
F2
ORN
761
F3
--
--
F4
DK GRN/WHT
762
A/C Request Signal
F5
WHT
193
F6
BLK/WHT
1704
F7
DK GRN
734
F8
LT GRN/BLK
735
F9
TAN
1812
HVAC Control Assembly Return - Passenger
F10
LT BLU/BLK
590
F11
--
--
F12
PPL
1881
F13
--
--
F14
BLK
1878
F15
--
--
F16
DK BLU/WHT
831
Not Used
Not Used
Sensor Return

Not Used
Not Used
HVAC Control Assembly Signal - Clock Passenger
Not Used
HVAC Control Assembly Signal - Passenger
Heater and A/C Programmer (Oldsmobile with CJ2)
12089591
32 Way F Micro-Pack 100 Series
Pin
Wire Color
Circuit No.
E1
BLK/WHT
251
E2-E4
--
--
E5
DK GRN
835
E6
--
--
E7
DK GRN
835
Function
Ground
Not Used
Not Used
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Document ID: 359495
Page 8 of 12
Not Used
E8
--
--
E9
GRY/BLK
754
E10
TAN
800
E11
TAN
800
E12
BRN
1141
E13
ORN
40
E14
PPL/WHT
724
E15
GRY
1548
Passenger Solar Sensor Signal
E16
LT BLU
1880
F1
--
--
F2
ORN
761
F3
--
--
F4
DK GRN/WHT
762
A/C Request Signal
F5
WHT
193
F6
BLK/WHT
1704
F7
DK GRN
734
F8
LT GRN/BLK
735
F9
--
--
F10
LT BLU/BLK
590
F11
--
--
F12
PPL
1881
F13-F15
--
--
F16
DK BLU/WHT
831
Fused Output - IGN

Not Used
Not Used
Sensor Return
Not Used
Not Used
Not Used
Inside Air Temperature Sensor
12059252
2-Way M Metri-Pack 150 Series (RED)
Pin
Wire Color
Circuit No.
DK GRN
734
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Function
Document ID: 359495
BLK/WHT
Page 9 of 12
1704
Sensor Return
LH Sunload Temperature Sensor (Buick)
12047663
2-Way M Metri-Pack 150 Series (BLK)
Pin
Wire Color
Circuit No.
LT BLU/BLK
590
BLK/WHT
1704
Function
Sensor Return
LH Sunload Temperature Sensor (Oldsmobile)
12059254
2-Way M Metri-Pack 150 Series (GRN)
Pin
Wire Color
Circuit No.
LT BLU/BLK
590
BLK/WHT
1704
Function
Sensor Return
Passenger Temperature Control (Buick with CJ2)

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Document ID: 359495
Connector Part
Information
Page 10 of 12
12047934
8-Way F Metri-Pack 150 Series (LT GRY)
Pin
Wire Color
Circuit
No.
BRN
1141
TAN
1812
HVAC Control Assembly Return - Passenger
PPL/WHT
724
--
--
DK BLU/WHT
831
BLK
1878
GRY
BLK
1450
Function
Vacuum Flourescent Dimming Signal

Not Used
HVAC Control Assembly Signal - Clock Passenger
Ground
Passenger Temperature Control (Oldsmobile with CJ2)

Pin
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Wire Color
12162143
Circuit No.
Function
Document ID: 359495
Page 11 of 12
DK BLU/WHT
831
BLK/WHT
1704
GRY
BLK
1450

Sensor Return
Ground
RH Sunload Temperature Sensor (Buick)
12047663
Pin
Wire Color
Circuit No.
Function
GRY
1548
Solar Sensor Signal - Passenger
BLK/WHT
1704
Sensor Return
RH Sunload Temperature Sensor (Oldsmobile)
12059254
2-Way M Metri-Pack 150 Series (GRN)
Pin
Wire Color
Circuit No.
GRY/BLK
1548
Solar Sensor Signal - Passenger
BLK/WHT
1704
Sensor Return
B
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Function
Document ID: 359495
Page 12 of 12
Sunload Temperature Sensor (Pontiac)
12047663
Pin
Wire Color
Circuit No.
LT BLU/BLK
590
BLK/WHT
1704
Function
Sensor Return
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Document ID: 297111
Page 1 of 1

HVAC Systems - Automatic | Repair Instructions | Document ID: 297111
Refrigerant Recovery and Recharging

Tools Required
J 39500-B Air Conditioning Refrigerant Recovery, Recycling and Recharging (ACR4) System
J 41810 Pure Guard 2
J 41810-100A Active Flow Control
Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to
remove R-134a from the A/C system, use service equipment that is certified to meet the
requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge
occurs, ventilate the work area before continuing service. Additional health and safety information
may be obtained from the refrigerant and lubricant manufacturers.
Caution: For personal protection, goggles and lint-free gloves should be worn and a clean cloth
wrapped around fittings, valves, and connections when doing work that includes opening the
refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and
personal injury can result. The exposed area should be flushed immediately with cold water and
prompt medical help should be obtained.
Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.
Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation
through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor
failure is likely to occur. Refer to the manufacturer instructions included with the service equipment
before servicing.
The J 39500-B removes the Refrigerant-134a from the vehicle's A/C system. The recovery
procedure uses one filtering cycle. The evacuation procedure uses an automatic multiple pass
filtering cycle. The filtering cycles ensure a constant supply of clean and dry refrigerant for the A/C
system charging.
Refer to the J 39500-B ACR4 manual for operation and setup instructions.
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Document ID: 297112
Page 1 of 4

Air Conditioning Compressor Replacement

Removal Procedure
Tools Required
J 39500-B A/C Refrigerant Recovery, Recycling, and Recharging (ACR4) System
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
4. Remove the A/C compressor splash shield (1).
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Document ID: 297112
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5. Remove the transmission oil cooler line from the brackets.
6.
7.
8.
9.
Remove
Remove
Remove
Remove
the
the
the
the
retaining bolt from the A/C compressor hose.

wiring harness clip and reposistion.
front mounting nuts and the rear mounting bolt from the A/C compressor.
A/C compressor.
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Document ID: 297112
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1. Install the A/C compressor.

2. Install the mounting nuts to the A/C compressor.
Tighten
3. Install the mounting bolt to the A/C compressor.
Tighten
4. Install the retaining bolt to the A/C compressor hose.
Tighten
5. Install the wiring harness clip.
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Document ID: 297112
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6. Install the transmission oil cooler line into the brackets.
7. Install the A/C compressor splash shield (1).

8. Install the bolt.
Tighten
9.
10.
11.
12.
Lower the vehicle.

Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
Leak test the system. Refer to Leak Testing .
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Document ID: 259982
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Compressor Clutch Plate and Hub Assembly Removal

(V5 - Conventional Mount)
Tools Required
J 33022 6-Point 13 mm Socket
J 33027-A Clutch Hub Holding Tool
J 33013-B Hub And Drive Plate Remover/Installer
J 34992 Compressor Holding Fixture
1.
2.
3.
4.
Clamp the J 34992 in a vise.

Attach the A/C compressor to the holding fixture using the thumb screws.
Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning.
Use the J 33022 in order to remove the shaft nut.
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Document ID: 259982
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5. Thread the J 33013-B into the hub.

6. Use a wrench in order to hold the body of the J 33013-B .
7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and
hub assembly.
8. Remove the shaft key. Retain the shaft key for reassembly.
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Document ID: 259984
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Clutch Rotor and Bearing Removal (V5 - Conventional

Mount)
Tools Required
J 6083 External Snap Ring Pliers
J 9398 Rotor Bearing Remover
J 8092 Driver Handle
J 33020 Pulley Puller
J 33023-A Puller Pilot
1. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub
Assembly Removal (V5 - Conventional Mount) .
2. Use the J 6083 in order to remove the rotor and bearing assembly retaining ring.
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3. Install the J 33023-A to the front head.
4. Install the J 33020 into the inner circle of slots in the rotor.
5. Turn the J 33020 clockwise in the slots in order to engage the tangs of the puller with the
segments between the slots in the rotor.
6. Hold the J 33020 in place. Tighten the puller screw against the puller guide in order to
remove the puller rotor and bearing assembly.
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7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal.
7.1. Remove the forcing screw from the J 33020 .
7.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto
a solid, flat surface or blocks.
Notice: It is not necessary to remove the staking in front of the bearing to remove the
bearing, however, it will be necessary to file away the old stake metal for proper clearance
for the new bearing to be installed into the rotor bore or the bearing may be damaged.
8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub.
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Document ID: 259988
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Air Conditioning Clutch Coil Removal (V5 - Conventional

Mount)
Tools Required
J 6083 Snap Ring Pliers #24 External
J 8433-1 Puller Bar
J 8433-3 Forcing Screw
J 33025 Clutch Coil Puller Legs
Assembly Removal (V5 -- Conventional Mount) .
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Document ID: 259988
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Document ID: 259988
7.
8.
9.
10.
Page 3 of 3
Mark the location of the clutch coil terminal (1) on the compressor front head.
Install the J 33023-A on the front head of the compressor.
Install the J 8433-1 and theJ 8433-3 with the J 33025 on the front head of the compressor.
Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil (2).
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Document ID: 259995
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Compressor Control Valve Assembly Removal (V5 Conventional Mount)

Tools Required
J 5403 Snap Ring Pliers
1. Remove the control valve retaining ring using the J 5403 .

2. Remove the control valve assembly (5).
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Document ID: 260029
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Compressor Shaft Seal Removal (V5 - Conventional

Mount)
Tools Required
J 39400-A Electronic Halogen Leak Detector
J 9553-01 O-Ring Remover
J 23128-A Seal Seat Installer and Remover
Important: Do not change a shaft seal because of small amounts of oil found on an adjacent
surface. The seal allows some oil to pass for lubrication purposes. Change the shaft seal when the
following conditions exist:
A large amount of sprayed oil is found.
Actual refrigerant leak is found, using a J 39400-A or equivalent.
1. Install the compressor into the J 34992 .
Asssembly Removal (V5 -- Conventional Mount). .
3. Remove the shaft seal retaining ring using the J 5403 .

4. In order to prevent dirt or foreign material from damaging the compressor, thoroughly clean
the following parts:
The inside of the compressor neck area surrounding the shaft
The exposed portion of the seal
The compressor shaft
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Document ID: 260029
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The O-ring groove
Important: Securely hand-tighten the handle of the J 23128-A . Do not use a wrench or
pliers.
5. Fully engage the knurled tangs of the J 23128-A into the recessed portion of the seal by
turning the handle clockwise.
6. Remove the seal from the compressor using a rotary-pulling motion. Discard the seal.
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Document ID: 260029
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7. Remove the seal O-ring from the compressor neck using the J 9553-01 . Discard the seal Oring.
8. Inspect the shaft and the inside of the compressor neck again for dirt and foreign material.
9. Ensure that the shaft and the inside of the compressor neck are perfectly clean prior to
installing new parts.
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Document ID: 260031
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Compressor Pressure Relief Valve Removal (V5 Conventional Mount)

Tools Required
J 41790-A Compressor Holding Fixture
1. Install the compressor into the J 41790-A .
2. Remove the pressure relief valve (2) from the rear head of the compressor.
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Document ID: 260038
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Compressor Control Valve Assembly Install (V5 Conventional Mount)

Tools Required
1. Coat the O-rings with 525 viscosity refrigeration oil.

2. Using thumb pressure, push the O-rings in place.
3. Install the valve into the case.
Important: Ensure that the retaining ring is properly seated in the ring groove.
4. Using the J 5403 , install the valve retaining ring (5) with the high point of the curved sides
against the valve housing.
5. Perform a leak test. Refer to Compressor Leak Testing .
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Document ID: 260042
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Compressor Clutch Plate/Hub Assembly Install (V5 Conventional Mount)

Tools Required
J 33013-B Hub and Drive Plate Remover/Installer
J 33022 6-Shaft Nut Socket - 13mm
2. Install the shaft key (4) into the key groove of the clutch plate and hub (1).
Allow the key to project 3.2 mm (0.126 in) out of the key groove.
The shaft key is curved slightly in order to provide an interference fit in the key groove of
the hub.
3. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2).
4. Align the shaft key with the shaft keyway (3).
Notice: Do not drive or pound on the clutch hub or the shaft. Internal damage to the
compressor may result.
5. Place the clutch plate and hub assembly onto the compressor shaft.
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Document ID: 260042
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6.
7.
8.
9.
Remove the center screw from the J 33013-B .

Reverse the body direction of the center screw of the J 33013-B .
Install the J 33013-B with the bearing.
Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the
end of the compressor shaft.
10. Hold the center screw of the J 33013-B with a wrench.
Notice: If the center screw is threaded fully onto the end of the compressor shaft, or if the
body of the installer is held and the center screw is rotated, the key will wedge and will break
the clutch hub.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft.
Tighten the body of the J 33013-B several turns.
Remove the J 33013-B .
Verify that the shaft key remains in the keyway before installing the clutch plate and hub
assembly to the final position.
Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is
within 0.40-0.50 mm (0.016-0.020 in).
Verify that the shaft key is even with or slightly above the clutch hub.
Install the shaft nut.
Hold the clutch plate and hub assembly with the J 33027-A .
20. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 Nm (12.5 lb ft) torque
wrench and the J 33022 .
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Tighten
Tighten the nut to 16.5 Nm (12 lb ft).
21. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive
plate.
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Document ID: 260048
Page 1 of 4

Clutch Rotor and/or Bearing Install (V5 - Conventional

Mount)
Tools Required
J 6083 #24 External Snap Ring Pliers
J 8433-1 Puller Bar
J 9481-A Bearing Installer
J 21352-A Support Block
J 33017 Pulley And Bearing Assembly Installer
J 33019 Bearing Staking Tool
Notice: Do not support the rotor by resting the pulley rim on a flat surface during the
bearing installation or the rotor face will be bent.
1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the
bearing installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub.
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The J 9481-A applies force to the outer race of the bearing.
4. Place the J 33019 and the staking pin in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under
the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 .
Important: Do not allow a metal stake to contact the outer face of the bearing in order to
prevent distortion of the outer race.
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . Properly position
the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed
down to, but not touching, the bearing.
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Document ID: 260048
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9. Stake 3 places 120 degrees apart.
10. With the compressor mounted to the J 34992 , position the rotor and bearing assembly on
the front head.
11. Position the J 33017 and the J 33023-A directly over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A .
13. Assemble the 2 through bolts and the washers of the J 34992 through the slots of the J
8433-1 .
14. Thread the 2 through bolts into the J 34992 .
Ensure that the thread of the through bolts engages the full thickness of the J 34992 .
15. Tighten the J 8433-3 in the J 8433-1 in order to force the pulley rotor and bearing assembly
onto the front head of the compressor.
16. If the J 33017 slips off direct, in-line contact with inner face of the bearing, use the following
steps:
16.1. Loosen the J 8433-3 .
16.2. Realign the J 33017 and the J 33023-A in order to ensure that the installer clears the
front head.
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Document ID: 260048
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17. Install the rotor and bearing assembly retainer ring using the J 6083 .
18. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub
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Document ID: 260051
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Air Conditioning Clutch Coil Installation (V5 Conventional Mount)

Tools Required
J 8433-1 Puller Bar
J 33024 Clutch Coil Installer Adapter
1. Place the clutch coil assembly on the front head with the terminals positioned at the marked
location.
2. Place the J 33024 over the internal opening of the clutch coil housing.
3. Align the J 33024 with the compressor front head.
4. Center the J 8433-1 on the countersunk center hole of the J 33024 .
5. Install the through bolts and the washers of the J 34992 through the slots in the J 8433-1 .
6. Thread the through bolts into the J 33025 in order to achieve full fixture thickness.
Important: Ensure that the clutch coil and the J 33024 stay in-line during the installation.
7. Turn the J 8433-3 of the J 8433-1 in order to force the clutch coil onto the head.
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8. With the compressor still mounted to the J 34992 and the coil seated on the front head,
stake the front head using a drift punch with a diameter of 3.175 mm (0.125 in).
9. Stake the front head at 3 places 120 degrees apart in order to ensure that the clutch coil
remains in position.
10. Ensure that the stake size is only one half of the area of the punch tip and only 0.280.35 mm (0.010-0.015 in) in depth.
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Document ID: 260051
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the front head.
8433-1 .
steps:
17.1. Loosen the J 8433-3 .
front head.
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20. Install the shaft nut.
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Document ID: 260053
Page 1 of 3

Compressor Shaft Seal Install (V5 - Conventional

Mount)
Tools Required
J 23128-A Seal Seat Installer And Remover
J 33011 O-Ring Installer
J 34614 Shaft Seal Protector
Notice: Seals should not be re-used. Always use a new specification service seal kit. Be sure
that the seal to be installed is not scratched or damaged in any way. Make sure that the seal
is free of lint and dirt that could damage the seal surface or prevent sealing.
1. Thoroughly clean the seal O-ring groove in the front head.
2. Dip the new seal O-ring in clean 525 viscosity refrigerant oil.
Notice: Any attempt to use makeshift or inadequate service tools or equipment may result in
damage and/or improper compressor operation.
3. Assemble the O-ring onto the J 33011 .
4. Install the O-ring.
4.1. Insert the J 33011 into the compressor neck until the installer bottoms out.
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Important: The top groove in the compressor neck is for the shaft seal retainer ring.
Document ID: 260053
Page 2 of 3
4.2. Lower the moveable slide of the J 33011 in order to release the O-ring into the seal Oring lower grove.
4.3. Rotate the J 33011 in order to seat the O-ring.
4.4. Remove the installer.
5. Dip the new shaft seal in clean 525 viscosity refrigerant oil.
6. Assemble the seal to the J 23128-A by turning the handle clockwise.
6.1. Ensure that the stamped steel case side of the lip seal engages with the knurled tangs
of the J 23128-A .
6.2. Ensure that the flared-out side of the lip seal faces toward the compressor.
Notice: Use care when handling the seal protector. Do not nick the seal protector. This may
damage the seal during installation. Ensure that the bottom of the seal protector is not
flared. This may damage the seal during installation.
7. Install the J 34614 on the lip seal.
8. Install the lip seal onto the shaft.
8.1. Place the J 34614 over the end of the compressor shaft.
8.2. Slide the new seal onto the shaft using a rotary motion of the J 23128-A .
8.3. Ensure that the seal makes good contact with the O-ring.
Do not dislodge the O-ring.
8.4. Disengage the J 23128-A from the seal.
8.5. Remove the J 23128-A and the J 34614 from the compressor.
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9. Use the J 5403 in order to install the new seal retainer ring with the flat side against the seal.
10. Use the sleeve of theJ 33011 in order to press in the seal retainer ring. Ensure that the ring
11. Leak test the compressor. Refer to Compressor Leak Testing (V5 -- Conventional Mount).
12. Remove any excess oil from the shaft and the inside of the compressor neck.
13. Install the clutch plate and hub assembly. Refer to Compressor Leak Testing (V5 -Conventional Mount).
14. Install the compressor and the compressor belt. Tighten the bracket.
15. Evacuate and charge the refrigerant system using the J 39500-B .
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Document ID: 260059
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Compressor Pressure Relief Valve Installation (V5 Conventional Mount)
1. Clean the valve seat area on the rear head.

2. Lubricate the O-ring of the new pressure relief valve and the O-ring assembly using new 525
viscosity refrigerant oil.
3. Install the new pressure relief valve (2).
Tighten
Tighten the valve to 9 Nm (80 lb in).
4. Perform a leak test. Refer toCompressor Leak Testing (V5 -- Conventional Mount) .
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Document ID: 260063
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Compressor Leak Testing (V5 - Conventional Mount)

Tools Required
J 39400 Electronic Halogen Leak Detector
J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System
J 39893 Pressure Testing Connector
With the sealing washers in place, install the J 39893 on the rear head of the compressor.
Connect the gage charging lines and the J 39500-B .
Pressurize the suction and the high-side of the compressor using R-134a refrigerant.
With the compressor in a horizontal position, rotate the compressor shaft several turns by
hand in the operating direction.
5. Using the J 39400 , inspect for leaks at the following locations:
The pressure relief valve
1.
2.
3.
4.
The rear head switch

The front head seal
The rear head seal
The through bolt head gaskets
6.
7.
8.
9.
10.
The compressor shaft seal

Perform the measures necessary to correct any external leaks found.
Inspect for leaks again following any repair.
Recover the refrigerant.
Disconnect the hoses from the J 39893 .
Remove the J 39893 .
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Document ID: 297114
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Air Conditioning Compressor Bracket Replacement

Removal Procedure
1. Remove the A/C compressor. Refer to Compressor Replacement .

2. Remove the retaining bolts (1,3) from the A/C compressor mounting bracket.
3. Remove the A/C compressor mounting bracket.
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Document ID: 297114
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1. Install the A/C compressor mounting bracket.

2. Install the retaining bolts (1,3) to the A/C compressor mounting bracket.
Tighten
Tighten the side bracket bolts to 100 Nm (74 lb ft).
Tighten the front bracket bolt to 50 Nm (37 lb ft).
3. Install the A/C compressor. Refer to Compressor Replacement
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Document ID: 297113
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O-Ring Replacement
Removal Procedure
Tools Required
J 38042 Dual O-Ring Joint Separator
2. Place the J 38042 on the refrigerant line directly behind the female nut of the dual O-ring
joint.
Hold pressure against the nut.
3. Loosen the female nut until the seal of the dual O-ring joint is broken. This procedure aids in
the seal separation.
4. After the seal is broken, slightly tighten the female nut to facilitate the J 38042 removal.
5. Remove the female nut. Separate the connection.
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6. Use a non-metallic tool to remove the O-rings.

The use of a non-metallic tool minimizes the chance of impairing the seal surfaces.
7. Inspect the line for kinks and dents.
8. Inspect the connection for the burrs and nicks.
Tools Required
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Document ID: 297113
1.
2.
3.
4.
5.
Page 3 of 3
Lubricate the O-rings using 525 oil or mineral oil before installation.
Install the O-rings.
Oil the bore using a small amount of refrigerant oil before assembly.
Align the end forms for pilot-to-bore insertion.
Push the pilot and the bore together completely.
6. Install the female nut.

Tighten
Tighten the nut to 24 Nm (18 lb ft).
7. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
8. Leak test the system. Refer to Leak Testing .
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Document ID: 297115
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Air Conditioning Compressor Hose Replacement

Removal Procedure
Tools Required
3. Remove the upper A/C

line clip (1).
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4. Disconnect the A/C line connection from the accumulator outlet using the J 38042 .
5. Disconnect the A/C line connection from the condenser inlet using the J 38042 .
6. Remove the A/C compressor splash shield.
7. Disconnect the electrical connector from the A/C pressure switch (4).
8. Remove the bolt (2) that attaches the A/C compressor hose assembly (3), from the rear of
the A/C compressor (1).
9. Remove the A/C compressor hose assembly (3) from the vehicle.
Tools Required
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1. Install the A/C compressor hose assembly (3) into the vehicle.
2. Install the bolt (2) in order to attach the A/C compressor hose assembly (3) to the rear of the
A/C compressor (1).
Tighten
3. Connect the electrical connector to the A/C pressure switch (4).
4. Connect the A/C line connection to the condenser inlet.
Tighten
Tighten the condenser inlet connection to 24 Nm (18 lb ft).
5. Connect the A/C line connection to the accumulator outlet.
Tighten
Tighten the accumulator outlet connection to 24 Nm (18 lb ft).
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6. Install the upper A/C line clip (1).

Tighten
Tighten the negative battery cable to 15 Nm (11 lb ft).
9. Test the A/C system for leaks. Refer to Leak Testing .
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Document ID: 297115
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Document ID: 297116
Page 1 of 4

Expansion (Orifice) Tube Replacement

Removal Procedure
Tools Required
J 26549-E Expansion Tube Remover
2. Remove the dual O-ring joint (1) of the condenser outlet using the J 38042 .
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Document ID: 297116
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3. Remove the dual O-ring joint of the evaporator inlet using the J 38042 .
4. Remove the A/C line clips.
Object Number: 247323 Size: SH
5. Remove the expansion tube from the line using the J 26549-E .
Tools Required
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1. With the short screen toward the evaporator, install the expansion tube.
2. Position the line and install the A/C line clips.
3. Assemble the dual O-ring joints of the evaporator inlet and the condenser outlet (1).
4. Hand tighten the dual O-ring joints in order to assure correct line orientation.
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5. Tighten the dual O-ring connections.

Tighten
Tighten the dual O-ring connections to 24 Nm (18 lb ft).
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Document ID: 297117
Page 1 of 2

Air Conditioning (A/C) Refrigerant Pressure Sensor

Replacement
Removal Procedure
1. Disconnect the electrical connection from the switch (1).

2. Remove the following components:
The switch
The O-ring seal
1. Lubricate the O-ring using clean 525 oil or mineral oil.
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2. Install the O-ring seal.

3. Install the switch (1).
Tighten
Tighten the switch to 5 Nm (44 lb in).
4. Connect the electrical connection to the switch (1).
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Air Conditioning Condenser Replacement

Removal Procedure
Tools Required
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
4. Remove the bolts (1) from the upper radiator panel.

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Document ID: 297118
6.
7.
8.
9.
10.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
Page 2 of 3
inlet line from the condenser (5).

outlet line from the condenser (5).
nuts (1) and the bolts (3) from the mounting brackets (2).
upper insulators (4).
condenser (5) by tilting the radiator toward the engine.
1. Install the condenser (5) into position by tilting the radiator toward the engine.
2. Install the upper insulators (4).
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3. Install the nuts (1) and the bolts (3) to the mounting brackets (2).
Tighten
4. Install the outline line to the condenser (5).
5. Install the inlet line to the condenser.
Tighten
Tighten the condenser connections to 24 Nm (18 lb ft).

7. Install the upper radiator panel bolts (1).
Tighten
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
9. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
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Document ID: 297120
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Air Conditioning Accumulator Replacement

Removal Procedure
Tools Required
2. Remove the cross car support brace. Refer to Cross Vehicle Brace Replacement in Body Front
End.
3.
4.
5.
6.
Remove the sight shield of the rear engine.

Loosen the retaining clamp screw.
Use the J 38042 to disconnect the accumulator inlet and outlet connections.
Remove the retaining clamp screw.
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7. Remove the accumulator (1).
Tools Required
1. Install the accumulator (1).

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2. Install the retaining clamp screw.
Tighten
Tighten the screw to 6 Nm (53 lb in).
3. Connect and torque the accumulator inlet and outlet connections.
Tighten
Tighten the accumulator connections to 34 Nm (25 lb ft).
4.
5.
6.
7.
Install the sight shield of the rear engine.

Install the cross car brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
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Document ID: 297496
Page 1 of 1

Blower Motor Control Module Replacement

Removal Procedure
1.
2.
3.
4.
5.
6.

Remove the rear engine sight shield.
Disconnect the positive booster cable from the multi-use relay center.
Move the underhood fuse block out of the way.
Disconnect the electrical connectors from the blower control module.
Remove the blower control module from the blower module.
1.
2.
3.
4.
5.
Install the blower control module to the blower module.

Connect the electrical connectors to the blower control module.
Move the underhood fuse block to the original position before removal.
Connect the positive booster cable to the multi-use relay center.
Install the rear engine sight shield.

Tighten
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Blower Motor and Fan Replacement

Removal Procedure
End.
2. Remove the rear spark plug wires and bracket and set aside.
3.
4.
5.
6.
Disconnect the electrical connector (5) from the blower motor (2).
Remove the cooling tube (4) from the blower motor (2).
Remove the screws (3) that attach the blower motor (2) to the blower module assembly (1).
Remove the blower motor (2).
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1. Install the blower motor (2).

2. Install the screws (3) to the blower motor (2).
Tighten
Tighten the screws to 6 Nm (55 lb in).
3.
4.
5.
6.
Install the cooling tube (4) to the blower motor (2).

Connect the electrical connector (5) to the blower motor (2).
Install the rear spark plug wires and bracket.
Install the cross car support brace. Refer to Cross Vehicle Brace Replacement in Body Front
End.
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Document ID: 297125
Page 1 of 4

HVAC Module Assembly Replacement

Removal Procedure
Tools Required
J 37097-A MUBEA Hose Clamp Pliers
End.
3. Remove the IP assembly. Refer to Instrument Panel Assembly Removal in Instrument Panel,
Gauges and Console.
5. Disconnect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness
Replacement in Engine Electrical.
6. Remove the evaporator. Refer to Evaporator Core Replacement .
7. Remove the heater hoses from the heater core using the J 37097-A .
8. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power
Steering Systems.
9. Remove the air distributor. Refer to Air Distributor Duct Replacement .
10. Remove the aspirator adapter (C68 and CJ2).
11. Remove the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
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12. Remove the bolts (5) that attach the heater and A/C module assembly (3) to the front of the
dash (4).
13. Remove the bolts (1) and the studs (2) that attach the heater and A/C assembly (3) to the
front of the dash (4).
14. Reposition the insulation as needed.
15. Remove the remainder of the heater and A/C module assembly (3).
Rotate the assembly (3) as needed to clear the right rear corner of the engine.
16. If replacing the heater and A/C module assembly (3), transfer the heater core to a new
module assembly (3).
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1. Install the heater and A/C module assembly (3) (partial).

2. Install the bolts (1) and the studs (2) to attach the heater and A/C module assembly (3) to
the rear of the dash (4).
Reposition the insulation as needed.
Tighten
Tighten the bolts and the studs to 5 Nm (44 lb in).
3. Install the bolts (5) to attach the heater and A/C module assembly (3) to the front of the
dash (4).
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Tighten
4.
5.
6.
7.
8.
Install the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
Install the aspirator adapter (C68 and CJ2).
Install the air distributor. Refer to Air Distributor Duct Replacement .
Install the vacuum source input to the right side of the air distributor.
Install the power steering pump. Refer to Power Steering Pump Replacement in Power
Steering Systems.
9. Install the heater hoses to the heater core using the J 37097-A .
10. Install the evaporator. Refer to Evaporator Core Replacement .
11. Connect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness
12. Install the IP assembly. Refer to Instrument Panel Assembly Removal in Instrument Panel,
Gauges and Console.
13. Install the cross car brace support. Refer to Cross Vehicle Brace Replacement in Body Front
End.
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
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Air Conditioning Evaporator Core Replacement

Removal Procedure
Tools Required
End.
3. Remove the fuse block cover.

4. Remove the accumulator. Refer to Accumulator Replacement .
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Document ID: 297126
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5. Remove the positive booster cable from the multi-use relay center.
6. Position the under hood fuse block out of the way.
7.
8.
9.
10.
11.
12.
Remove the evaporator tube from the evaporator.

Remove the wire harness clip from the HVAC module.
Remove the accumulator bracket.
Remove the heat shield of the HVAC module.
Following the cut line, cut the top side of the HVAC module cover.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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Document ID: 297126
13.
14.
15.
16.
17.
Page 3 of 6
Following the cut line, cut the bottom side of the HVAC module cover.
Lower the vehicle.
Remove the fuel line clip from the HVAC module.
Remove the insulator from the module.
Remove the bolt that attaches the heater and A/C module assembly to the inside of the
vehicle.
Remove the blower module from the HVAC module assembly.
18. Remove the evaporator core.
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Installation
Procedure
Document ID: 297126
Page 4 of 6
1. Install the evaporator core.

2. Install the blower module to the HVAC module assembly.
Tighten
4. Install the bolt to attach the heater and A/C module assembly to the inside of the vehicle.
Tighten
5.
6.
7.
8.
Install
Install
Install
Install
the
the
the
the
insulator to the module.

fuel line clip to the HVAC module.
HVAC module heat shield.
bolts.
Tighten
9. Install the accumulator bracket.
10. Install the screws.
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Tighten
11. Install the wire harness clip to the HVAC module.
12. Install the evaporator tube to the evaporator.

Tighten
Tighten the evaporator tube connection to 24 Nm (18 lb ft).
13. Reposition the under hood fuse block to the original position.
14. Install the booster cable from the multi-use relay center.
15. Install the accumulator. Refer to Accumulator Replacement .
16. Install the fuse block cover.
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Document ID: 297126
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17. Install the cross car support. Refer to Cross Vehicle Brace Replacement in Body Front End.
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Document ID: 297127
Page 1 of 4

Heater Core Replacement

Removal Procedure
Tools Required
J 37097-A Hose Clamp Pliers
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Remove the heater hoses (2) from the heater core using the J 37097-A .
4. Remove the I/P compartment. Refer to Instrument Panel Storage Compartment Replacement
in Instrument Panel, Gauges and Console.
5. Remove the temperature valve actuator. Refer to Temperature Actuator Replacement .
6. Remove the HVAC programmer (C68). Refer to Programmer Replacement
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Document ID: 297127
7.
8.
9.
10.
Remove
Remove
Remove
Remove
the
the
the
the
heater
heater
heater
heater
Page 2 of 4
core cover retaining screws.

core cover.
core retaining screws.
core.
1. Install the heater core into the vehicle.
2. Install the attaching screws.
Tighten
Tighten the screws to 1.4 Nm (12 lb in).
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3. Install the heater core cover.

Tighten
5. Install the HVAC programmer (C68). Refer to Programmer Replacement
6. Install the temperature valve actuator. Refer to Temperature Actuator Replacement .
8. Install the I/P compartment. Refer to Instrument Panel Storage Compartment Replacement
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Document ID: 297127
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9. Install the heater hoses (2) to the heater core using the J 37097-A .
10. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
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Document ID: 401717
Page 1 of 3

Control Assembly Replacement (Buick)

Removal Procedure
1. Remove the I/P cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement in
Instrument Panel, Guages and Console.
2. Remove the retaining screws from the HVAC control assembly.

3. Pull the assembly out from the instrument panel.
4. Disconnect the electrical connector and remove the HVAC control assembly.
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1. Connect the electrical connector to the HVAC control assembly.
2. Install the HVAC control assembly into the instrument panel.

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3. Install the retaining screws to secure the HVAC control assembly.

Tighten
4. Install the I/P cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement in
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Document ID: 297480
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Control Assembly Replacement - Passenger (Buick)

Removal Procedure
1. Remove
Doors.
2. Remove
3. Remove
4. Remove
the door handle insert. Refer to Front Side Door Trim Panel Insert Replacement in
the right door pad. Refer to Front Side Door Trim Panel Replacement in Doors.
the 2 retaining screws.
the passenger climate control.
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Document ID: 297480
1.
2.
3.
4.
Install the
Install the
Install the
Install the
Doors.
Page 2 of 2
passenger climate control.

2 retaining screws.
right door pad. Refer to Front Side Door Trim Panel Replacement in Doors.
door handle insert. Refer to Front Side Door Trim Panel Insert Replacement in
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Document ID: 297481
Page 1 of 2

Programmer Replacement (Buick, Oldsmobile)

Removal Procedure
in Instrument Panel, Guages and Console.
2. Remove the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel, Guages and Console.
3.
4.
5.
6.
7.
Disconnect the electrical connectors (7).

Disconnect the vacuum connectors (9).
Remove the rod from the driver temperature valve link (11).
Remove the screws (8) that mount the programmer (6) to the vehicle.
Remove the programmer (6).
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1. Install the programmer (6) into position.

2. Install the screws (8) in order to secure the programmer (6).
Tighten
3.
4.
5.
6.
7.
Connect the electrical connectors (7).

Connect the vacuum connectors (9).
Install the rod to the driver temperature valve link (11).
Adjust the rod to the temperature valve link. Refer to Temperature Valve Link Adjustment .
Install the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel, Guages and Console.
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Document ID: 297482
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Temperature Actuator Replacement

Removal Procedure
1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal in
2. Remove the temperature valve link rod (1) from the temperature valve by snapping the rod
out of the valve.
3. Disconnect the electrical connector (3) from the A/C temperature valve actuator (4).
4. Remove the screws (2) which retain the actuator to the heater and A/C module (5).
5. Remove the actuator.
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1. Install the A/C temperature and valve actuator (4) to the heater and A/C module (5).
Tighten
3. Connect the electrical connector (3) to the A/C temperature valve actuator.
Important: Adjust the temperature valve link rod prior to installation. Refer to Temperature
Valve Link Adjustment
4. Install the temperature valve link rod (1) to the temperature valve, by snapping the rod into
place.
5. Install the instrument panel assembly. Refer to Instrument Panel Assembly Removal in
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Document ID: 297131
Page 1 of 2

Heater/Bi-Level Actuator Replacement

Removal Procedure
1. Remove the air distributor assembly. Refer to Air Distributor Duct Replacement .
2. Remove the clip and the screws that fasten the 2 halves of the air distributor assembly:
Separate the air distributor assembly.

In order to disconnect the vacuum actuator (5) from the air distributor assembly, unclip
and disengage the vacuum actuator (5) from the valve.
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1. In order to connect the vacuum actuator (5) to the air distributor assembly, clip and engage
the vacuum actuator to the valve.
2. Fasten the 2 halves of the air distributor assembly.
Tighten
3. Install the air distributor assembly. Refer to Air Distributor Duct Replacement .
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Document ID: 297483
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Air Inlet Actuator Replacement

Removal Procedure
1. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement Left Side in Instrument Panel, Guages and Console.
2. Disconnect the vacuum hose from the outside air/recirculation actuator (1).
3. Unclip the outside air/recirculation actuator (1) from the air inlet.
4. Disengage the outside air/recirculation actuator (1) from the valve.
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1. Engage the outside air/recirculation actuator (1) to the valve.

2. Clip the outside air/recirculation actuator (1) to the air inlet.
3. Connect the vacuum hose to the outside air/recirculation actuator (1).
Install the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Guages and Console.
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Document ID: 297484
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Defroster Valve Actuator Replacement

Removal Procedure
1. Remove the air distributor assembly. Refer to Air Distributor Duct Replacement
2. Unclip the defrost-A/C actuator (3) from the air inlet.

3. Disengage the defrost-A/C actuator (3) from the valve.
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1. Engage the defrost-A/C actuator (3) to the valve.

2. Clip the defrost-A/C actuator to the air inlet.
3. Install the air distributor assembly. Refer to Air Distributor Duct Replacement
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Document ID: 297487
Page 1 of 2

Air Mix Actuator Replacement - Passenger

Removal Procedure
1. Remove the instrument panel compartment. Refer to Instrument Panel Storage Compartment
Replacement in Instrument Panel, Guages and Console.
2. Remove the temperature valve link rod (2) from the plastic retainer on the temperature
valve.
4.1. The screws (3) that mount the passenger air mix valve actuator (4) to the vehicle.
4.2. The passenger air mix valve actuator (4).
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Document ID: 297487
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1. Install the passenger air mix valve actuator (4) to the vehicle.
2. Install the screws (3) in order to secure the passenger air mix valve actuator (4) to the
vehicle.
Tighten
4. Install the temperature valve link rod (2).
5. Adjust the passenger temperature valve link rod. Refer to Temperature Valve Link
Adjustment - Passenger .
6. Install the instrument panel compartment. Refer to Instrument Panel Storage Compartment
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Document ID: 297488
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Temperature Valve Link Adjustment

1. If you have not already disassembled the valve link, pull the valve link from the retainer on
the programmer output crank.
2. Start the vehicle.
Set the temperature to 32C (90F).
3. Allow a minimum of 45 seconds in order for the programmer motor to move the output crank
to the full hot position.
4. Move the temperature valve to the full hot position.
5. Snap the valve link into the retainer on the output crank.
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Document ID: 297489
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Temperature Valve Link Adjustment - Driver

1. Start the vehicle.
2. Set the temperature to 32C (90F) at the heater and A/C control.
3. Set the passenger temperature control to full warm.
Refer to the following list:
If the outside temperature is above 32C (90F), disconnect the inside temperature
sensor.
Allow 45 seconds in order for the air mix valve actuators to move to the warm position.
4. Gently pull the driver temperature valve link (11) toward the programmer (6) until the valve
hits the stop.
5. Push the threaded portion of the link into the slot of the driver temperature valve crank.
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Document ID: 297490
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Temperature Valve Link Adjustment - Passenger
out of the valve.
2. Start the vehicle. Make the following settings:
Set the fan to position IIII (HIGH).
Set the temperature to full hot.
3. Allow 45 seconds minimum for the A/C temperature valve actuator (4) to move to the full hot
position.
5. Snap the temperature valve link rod into the temperature valve.
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Document ID: 297139
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Vacuum Electrical Solenoid Replacement

Removal Procedure
1. Perform the following steps in order to swing down the IP compartment:

1.1. Pull the IP compartment rearward.
2.
3.
4.
5.
1.2. Disengage the swing stops.

Disconnect the vacuum harness connector (3) from the solenoid (1).
Disconnect the electrical connector (2) from the solenoid (1).
Remove the screws (4) from the solenoid (1).
Remove the solenoid (1) from the heater and A/C module (5).
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1. Install the solenoid (1) to the heater and A/C module (5).
2. Install the screws (4) to the solenoid (1).
Tighten
3. Connect the electrical connector (2) to the solenoid (1).
4. Connect the vacuum harness connector (3) to the solenoid (1).
5. Push forward on the IP compartment in order to install the IP compartment.
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Document ID: 297143
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Air Inlet Assembly Replacement

Removal Procedure
2. Remove the bolts (2) that attach the air inlet (3) to the dash panel (1) and to the front of the
dash.
3. Reposition the insulation as needed to remove the air inlet assembly (3).
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Document ID: 297143
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1. Position the air inlet (3) in the vehicle.

3. Install the bolts (2) to attach the air inlet (3) to the dash panel (1) and to the front of the
dash.
Refer to the illustration for the proper tightening sequence.
Tighten
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Document ID: 297134
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Air Distributor Duct Replacement

Removal Procedure
Guages and Console.
2. Remove the screws (1) from the center air distributor (2).
3. Remove the center air distributor (2).
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Document ID: 297134
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1. Install the center air distributor (2).

Tighten
Guages and Console.
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Document ID: 297135
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Crosscar Air Outlet Replacement

Removal Procedure
Gauges and Console.
2. Remove the duct mounting screws (1).

3. Remove the duct (2).
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1. Install the duct (2).

2. Install the duct mounting screws (1).
Tighten
3. Install the side window defogger adapters.
Gauges and Console.
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Document ID: 297491
Page 1 of 2

Ambient Temperature Sensor Replacement

Removal Procedure
1. Disconnect the electrical connector (5) from the ambient air temperature sensor (3).
2. Remove the bolt (4) that retains the ambient air temperature sensor (3) to the upper
radiator tie bar (1).
3. Remove the ambient air temperature sensor (3).
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Document ID: 297491
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1. Install the bolt (4) to retain the ambient air temperature sensor (3) to the upper radiator tie
bar (1).
Tighten
2. Connect the electrical connector (5) to the sensor (3).
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Document ID: 297492
Page 1 of 2

Inside Air Temperature Sensor Replacement (Buick)

Removal Procedure
1. Remove the accessory panel trim plate. Refer to Instrument Cluster Trim Panel Replacement
2. Remove the aspirator hose and sensor assembly.
3. Remove the inside temperature sensor (1).
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Document ID: 297492
Page 2 of 2

2. Connect the inside temperature sensor (1) to the aspirator hose.
Important: Do not crimp or bend the hose during installation.
3. Connect the aspirator hose and sensor assembly to the instrument panel.
4. Install the accessory panel trim plate. Refer to Instrument Cluster Trim Panel Replacement in
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Document ID: 297494
Page 1 of 2

Sun Load Temperature Sensor Replacement (Buick)

Removal Procedure
1. Remove the defroster grille by prying up on the grille.
2. Remove the sun load sensor (1) from the defroster grille by twisting the sensor turn.
3. Disconnect the sun load sensor electrical connector.
4. Remove the sun load sensor (1).
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1. Connect the sun load sensor electrical connector.

2. Install the sun load sensor (1) to the defroster grille by twisting the sensor turn.
3. Install the defroster grille by snapping the grille into place.
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Document ID: 297067
Page 1 of 1

HVAC Systems - Manual | Specifications | Document ID: 297067

Specification
Application
Metric
English
Accumulator Retaining Bolt
6 Nm
53 lb in
Air Inlet Retaining Screws
5 Nm
44 lb in
A/C Compressor Hose Assembly Bolt
30 Nm
22 lb ft
A/C Module Cover Retaining Screws
3 Nm
27 lb in
Blower Resistance Assembly Screws
1.4 Nm
12 lb in
Compressor Mounting Bracket Front Bolt
50 Nm
37 lb ft
Compressor Mounting Bracket Side Bolts
100 Nm
74 lb ft
Condenser Mounting Brackets
12 Nm
106 lb in
Front Compressor Mounting Nuts
50 Nm
37 lb ft
Heater and A/C Vacuum Solenoid Screws
1.4 Nm
12 lb in
Heater Core Cover Screws
1.4 Nm
12 lb in
Rear Compressor Mounting Bolt
50 Nm
37 lb ft
Service Fitting
12 Nm
9 lb in
Temperature Valve Actuator Screws
1.4 Nm
12 lb in
Tighten All Dual O-ring Fittings
24 Nm
18 lb ft
Document ID: 297068
Page 1 of 1

System Capacities
Specification
Application
Refrigerant Capacity
Metric
English
0.91 kg
2.0 lb
Document ID: 297070
Page 1 of 1

Refrigerant Oil Distribution Specifications

Specification
Application
Metric
English
Accumulator
90 ml
3 oz
Compressor
60 ml
2 oz
Condenser
30 ml
1 oz
Evaporator
90 ml
3 oz
Document ID: 343257
Page 1 of 1

HVAC Systems - Manual | Component Locator | Document ID: 343257
Engine Compartment, Rear
(1) Blower Motor

(2) P101
(3) C101
10/22/2010
Document ID: 343258
Page 1 of 1

Engine Compartment, Right Rear Corner
(1) S104
(2) Blower Motor
(3) Blower Motor Resistor, Blower Control Module (Hidden)
(4) Blower Control Module
(5) Blower Motor Resistor
(6) S101
(7) S103
(8) S102
10/22/2010
Document ID: 343260
Page 1 of 1


(7) Horn Relay
10/22/2010
Document ID: 343268
Page 1 of 1

Engine, Front Side
(1) Knock Sensor Bank 1

(2) Starter Solenoid
(3) Engine Oil Level Switch
(4) A/C Pressure Sensor
(5) A/C Clutch
(6) A/C Clutch Diode
(7) S107
(8) S106
10/22/2010
Document ID: 400526
Page 1 of 1


Others Similar

(2) Cigar Lighter
(5) Radio
(7) Fog Lamp Switch
10/22/2010
Document ID: 392300
Page 1 of 9

HVAC Connector End Views

Table 1:
A/C Clutch
Table 2:
A/C Clutch Relay
Table 3:
A/C Pressure Sensor
Table 4:
Blower Motor High-Speed Relay
Table 5:
Blower Motor Relay
Table 6:
Blower Motor Resistor
Table 7:
Heater and A/C Control C1 (Buick with C67)
Table 8:
Table 9:
Heater and A/C Control C1 (Oldsmobile with C61)
Table 10: Heater and A/C Control C2 (Oldmobile with C61)

Table 11: Heater and A/C Control C3 (Oldsmobile with C61)
Table 12: Heater and A/C Control C1 (Pontiac with C61)
Table 13: Heater and A/C Control C2 (Pontiac with C61)
Table 14: Heater and A/C Vacuum Valve (Buick with C67)
Table 15: Temperature Valve Actuator
A/C Clutch
12162017
Pin
Wire Color
Circuit No.
DK GRN
59
BLK
1450
Function
A/C Compressor Clutch Solenoid Feed
Ground
A/C Clutch Relay
Document ID: 392300
Connector Part
Information
Page 2 of 9
12110787
4-Way F Metri-Pack 280 Series (MD GRA)
Pin
Wire Color
Circuit
No.
30
PNK
239
85
DK GRN/WHT
459
Air Conditioning Compressor Control Relay Output Ignition 1
86
PNK
239
87
DK GRN
59
Function
Air Conditioning Compressor Clutch Solenoid Feed
A/C Pressure Sensor
12110192
Pin
Wire Color
Circuit No.
Function
BLK
808
Sensor Return
GRY
474
5 Volt Reference Feed
RED/BLK
380
A/C Refrigerant Pressure Sensor Signal
Blower Motor High-Speed Relay
Document ID: 392300
Page 3 of 9
12110787
4-Way F Metri-Pack 280 Series (MD GRA)
Pin
Wire Color
Circuit No.
Function
30
BRN
41
85
BRN
41
86
BRN
247
87
LT BLU
1888
Blower Enable Relay Output - Coil

Cruise Control Servo Clutch Output
Blower Motor Relay
12110538
Pin
Wire Color
Circuit No.
Function
30
PPL
65
Blower Motor Feed
85
ORN
52
Blower Switch Output - High
86
BLK
1550
87
RED
442
87
DK BLU
101
Blower Resistor Output
Ground
Document ID: 392300
Page 4 of 9
Blower Motor Resistor
12048415
Connector Part
Information
Pin
Wire Color
Circuit
No.
DK BLU
101
LT BLU
72
Blower Switch Output - Medium 2
TAN
63
LT BLU
188
YEL
60
Function
Blower Resistor Output
Blower Enable Relay Output - N.O. Contact

(Buick)
Blower Switch Output - Low (Oldsmobile)
(Pontiac)
12064752
Pin
Wire Color
Circuit No.
--
--
Function
Not Used
Document ID: 392300
Page 5 of 9
TAN
63
ORN
52
LT BLU
72
LT BLU
188
--
--
Blower Enable Relay - N.O. Contact

Not Used
12110259
16 Way F Micro-Pack 100 Series (GRN)
Pin
Wire Color
Circuit No.
Function
A1
BRN
247
A2
DK BLU
1199
A3
GRY
A4
PPL/WHT
724
A5
--
--
A6
YEL
1791
Air Temperature Valve Motor Return
A7
BLK
1250
Ground
A8
BRN
1141
Fused Output-IGN
B1
WHT
193
B2
LT GRN
66
B3
PNK
1396
A/C Switch Signal-Defroster Solenoid Control
B4
LT GRN
1395
A/C Switch Signal-Vent Solenoid Control
B5
PPL
1397
A/C Switch Signal-Heat Solenoid Control
B6
DK GRN
1394
A/C Switch Signal-A/C Solenoid Control
B7-B8
--
--
Blower Enable Relay Output-Coil

Air Temperature Valve Motor Feed
Not Used
Rear Defogger Relay Output-Coil

A/C Switch Output
Not Used
Document ID: 392300
Page 6 of 9
12047886
Pin
Wire Color
Circuit No.
LT GRN
66
BLK
1250
ORN
40
GRA
YEL
1791
F-G
--
--
DK BLU
1199
Function
Air Conditioning Switch Output
Ground
Fuse Output - Battery - Type III Fuse
Not Used
Heater and A/C Control C2 (Oldmobile with C61)
12064752
Pin
Wire Color
Circuit No.
Function
WHT
193
BRN
41
Fuse Output - Ignition
ORN
60
Blower Switch Output - Low
Document ID: 392300
D-F
Page 7 of 9
--
--
Not Used
12020813
Pin
Wire Color
Circuit No.
Function
--
--
Not Used
ORN
52
TAN
63
LT BLU
72
YEL
60
Heater and A/C Control C1 (Pontiac with C61)
12015344
Pin
Wire Color
Circuit No.
Function
TAN
63
LT BLU
72
Document ID: 392300
Page 8 of 9
ORN
1140
Rear Defrost Blower Output - Medium 2
PPL
293
Rear Defrost Blower Output - Medium 1
BRN
41
Fuse Output - IGN - 3
YEL
60
Heater and A/C Control C2 (Pontiac with C61)
12065398
8-Way F Metri-Pack 150 Series (NAT)
Pin
Wire Color
Circuit No.
Function
LT GRN
66
BLK
1250
ORN
52
GRA
YEL
1791
BLK
1250
Ground
DK BLU
1199
Air Temperture Valve Motor Feed
BRN
41
Air Conditioning Switch Output

Ground
Heater and A/C Vacuum Valve (Buick with C67)
Object Number: 40427 Size: CH
Document ID: 392300
Page 9 of 9
12064978
Connector Part
Information
6-Way F Micro-Pack 100 Series (GRA)
Pin
Wire Color
Circuit
No.
DK GRN
1394
Air Conditioning Switch Signal - Air Conditioning

Solenoid Control
LT GRN
1395
Air Conditioning Switch Signal - Vent Solenoid Control
PNK
1396
Air Conditioning Switch Signal - Defrost Solenoid

Control
PPL
1397
Air Conditioning Switch Signal - Heat Solenoid Control
BRN
41
--
--
Not Used
Function
Temperature Valve Actuator

Object Number: 281207 Size: CH
12040953
6-Way F Micro-Pack 100 Series (BLK)
Pin
Wire Color
Circuit No.
Function
5-6
--
--
YEL
1791
DK BLU
1199
--
--
Not Used
10
BRN
41
Fused Output - Ignition 3 (Buick)
10
BRN
41
Fused Output - Ignition 3 (Oldsmobile)
Not Used
Document ID: 297111
Page 1 of 1

HVAC Systems - Manual | Repair Instructions | Document ID: 297111
Refrigerant Recovery and Recharging

Tools Required
J 39500-B Air Conditioning Refrigerant Recovery, Recycling and Recharging (ACR4) System
J 41810 Pure Guard 2
J 41810-100A Active Flow Control
Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to
remove R-134a from the A/C system, use service equipment that is certified to meet the
requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge
occurs, ventilate the work area before continuing service. Additional health and safety information
may be obtained from the refrigerant and lubricant manufacturers.
Caution: For personal protection, goggles and lint-free gloves should be worn and a clean cloth
wrapped around fittings, valves, and connections when doing work that includes opening the
refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and
personal injury can result. The exposed area should be flushed immediately with cold water and
prompt medical help should be obtained.
Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other
refrigerant may result in poor system performance or component failure.
Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation
through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If
lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor
failure is likely to occur. Refer to the manufacturer instructions included with the service equipment
before servicing.
The J 39500-B removes the Refrigerant-134a from the vehicle's A/C system. The recovery
procedure uses one filtering cycle. The evacuation procedure uses an automatic multiple pass
filtering cycle. The filtering cycles ensure a constant supply of clean and dry refrigerant for the A/C
system charging.
Refer to the J 39500-B ACR4 manual for operation and setup instructions.
Document ID: 297112
Page 1 of 4

Air Conditioning Compressor Replacement

Removal Procedure
Tools Required
2. Remove the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
4. Remove the A/C compressor splash shield (1).
Document ID: 297112
Page 2 of 4
5. Remove the transmission oil cooler line from the brackets.
6.
7.
8.
9.
Remove
Remove
Remove
Remove
the
the
the
the
retaining bolt from the A/C compressor hose.

wiring harness clip and reposistion.
front mounting nuts and the rear mounting bolt from the A/C compressor.
A/C compressor.
Document ID: 297112
Page 3 of 4
1. Install the A/C compressor.

2. Install the mounting nuts to the A/C compressor.
Tighten
3. Install the mounting bolt to the A/C compressor.
Tighten
4. Install the retaining bolt to the A/C compressor hose.
Tighten
5. Install the wiring harness clip.
Document ID: 297112
Page 4 of 4
6. Install the transmission oil cooler line into the brackets.

8. Install the bolt.
Tighten
9.
10.
11.
12.
Lower the vehicle.

Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
Document ID: 259982
Page 1 of 2

Compressor Clutch Plate and Hub Assembly Removal

(V5 - Conventional Mount)
Tools Required
J 33022 6-Point 13 mm Socket
J 33013-B Hub And Drive Plate Remover/Installer
1.
2.
3.
4.
Clamp the J 34992 in a vise.

Attach the A/C compressor to the holding fixture using the thumb screws.
Use the J 33027-A in order to prevent the clutch hub and drive plate assembly from turning.
Use the J 33022 in order to remove the shaft nut.
Document ID: 259982
Page 2 of 2
5. Thread the J 33013-B into the hub.

6. Use a wrench in order to hold the body of the J 33013-B .
7. Turn the center screw into the body of the J 33013-B in order to remove the clutch plate and
hub assembly.
8. Remove the shaft key. Retain the shaft key for reassembly.
Document ID: 259984
Page 1 of 3

Clutch Rotor and Bearing Removal (V5 - Conventional

Mount)
Tools Required
J 6083 External Snap Ring Pliers
J 9398 Rotor Bearing Remover
Assembly Removal (V5 - Conventional Mount) .
Document ID: 259984
Page 2 of 3
Document ID: 259984
Page 3 of 3
7. Support the rotor hub in order to prevent damage to the pulley rotor during bearing removal.
7.1. Remove the forcing screw from the J 33020 .
7.2. With the tangs of the J 33020 still engaged in the rotor slots, invert the assembly onto
a solid, flat surface or blocks.
Notice: It is not necessary to remove the staking in front of the bearing to remove the
bearing, however, it will be necessary to file away the old stake metal for proper clearance
for the new bearing to be installed into the rotor bore or the bearing may be damaged.
8. Use a J 9398 with the J 8092 in order to drive the bearing out of the rotor hub.
Document ID: 259988
Page 1 of 3

Air Conditioning Clutch Coil Removal (V5 - Conventional

Mount)
Tools Required
J 6083 Snap Ring Pliers #24 External
J 8433-1 Puller Bar
Document ID: 259988
Page 2 of 3
Document ID: 259988
7.
8.
9.
10.
Page 3 of 3
Mark the location of the clutch coil terminal (1) on the compressor front head.
Install the J 33023-A on the front head of the compressor.
Install the J 8433-1 and theJ 8433-3 with the J 33025 on the front head of the compressor.
Tighten the J 8433-3 against the J 33023-A in order to remove the clutch coil (2).
Document ID: 259995
Page 1 of 1

Compressor Control Valve Assembly Removal (V5 Conventional Mount)

Tools Required
1. Remove the control valve retaining ring using the J 5403 .

2. Remove the control valve assembly (5).
Document ID: 260029
Page 1 of 3

Compressor Shaft Seal Removal (V5 - Conventional

Mount)
Tools Required
J 39400-A Electronic Halogen Leak Detector
J 9553-01 O-Ring Remover
J 23128-A Seal Seat Installer and Remover
Important: Do not change a shaft seal because of small amounts of oil found on an adjacent
surface. The seal allows some oil to pass for lubrication purposes. Change the shaft seal when the
following conditions exist:
A large amount of sprayed oil is found.
Actual refrigerant leak is found, using a J 39400-A or equivalent.
Asssembly Removal (V5 -- Conventional Mount). .
3. Remove the shaft seal retaining ring using the J 5403 .

4. In order to prevent dirt or foreign material from damaging the compressor, thoroughly clean
the following parts:
The inside of the compressor neck area surrounding the shaft
The exposed portion of the seal
The compressor shaft
Document ID: 260029
Page 2 of 3
The O-ring groove
Important: Securely hand-tighten the handle of the J 23128-A . Do not use a wrench or
pliers.
5. Fully engage the knurled tangs of the J 23128-A into the recessed portion of the seal by
turning the handle clockwise.
6. Remove the seal from the compressor using a rotary-pulling motion. Discard the seal.
Document ID: 260029
Page 3 of 3
7. Remove the seal O-ring from the compressor neck using the J 9553-01 . Discard the seal Oring.
8. Inspect the shaft and the inside of the compressor neck again for dirt and foreign material.
9. Ensure that the shaft and the inside of the compressor neck are perfectly clean prior to
installing new parts.
Document ID: 260031
Page 1 of 1

Compressor Pressure Relief Valve Removal (V5 Conventional Mount)

Tools Required
J 41790-A Compressor Holding Fixture
1. Install the compressor into the J 41790-A .
2. Remove the pressure relief valve (2) from the rear head of the compressor.
Document ID: 260038
Page 1 of 1

Compressor Control Valve Assembly Install (V5 Conventional Mount)

Tools Required
1. Coat the O-rings with 525 viscosity refrigeration oil.

2. Using thumb pressure, push the O-rings in place.
3. Install the valve into the case.
Important: Ensure that the retaining ring is properly seated in the ring groove.
4. Using the J 5403 , install the valve retaining ring (5) with the high point of the curved sides
against the valve housing.
5. Perform a leak test. Refer to Compressor Leak Testing .
Document ID: 260042
Page 1 of 3

Compressor Clutch Plate/Hub Assembly Install (V5 Conventional Mount)

Tools Required
J 33013-B Hub and Drive Plate Remover/Installer
J 33022 6-Shaft Nut Socket - 13mm
2. Install the shaft key (4) into the key groove of the clutch plate and hub (1).
Allow the key to project 3.2 mm (0.126 in) out of the key groove.
The shaft key is curved slightly in order to provide an interference fit in the key groove of
the hub.
3. Clean the frictional surfaces of the clutch plate and hub and the clutch pulley rotor (2).
4. Align the shaft key with the shaft keyway (3).
Notice: Do not drive or pound on the clutch hub or the shaft. Internal damage to the
compressor may result.
5. Place the clutch plate and hub assembly onto the compressor shaft.
Document ID: 260042
Page 2 of 3
6.
7.
8.
9.
Remove the center screw from the J 33013-B .

Reverse the body direction of the center screw of the J 33013-B .
Install the J 33013-B with the bearing.
Back off the body of the J 33013-B in order to allow the center screw to be threaded onto the
end of the compressor shaft.
10. Hold the center screw of the J 33013-B with a wrench.
Notice: If the center screw is threaded fully onto the end of the compressor shaft, or if the
body of the installer is held and the center screw is rotated, the key will wedge and will break
the clutch hub.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Tighten the hex portion of the body of the J 33013-B in order to press the hub onto the shaft.
Tighten the body of the J 33013-B several turns.
Verify that the shaft key remains in the keyway before installing the clutch plate and hub
assembly to the final position.
Ensure that the gap between the frictional surfaces of the clutch plate and the clutch rotor is
within 0.40-0.50 mm (0.016-0.020 in).
Verify that the shaft key is even with or slightly above the clutch hub.
Install the shaft nut.
Hold the clutch plate and hub assembly with the J 33027-A .
20. Tighten the shaft nut against the crankshaft shoulder, using a 17.5 Nm (12.5 lb ft) torque
wrench and the J 33022 .
Document ID: 260042
Page 3 of 3
Tighten
Tighten the nut to 16.5 Nm (12 lb ft).
21. Spin the pulley rotor by hand in order to verify that the rotor does not rub the clutch drive
plate.
Document ID: 260048
Page 1 of 4

Clutch Rotor and/or Bearing Install (V5 - Conventional

Mount)
Tools Required
J 6083 #24 External Snap Ring Pliers
J 8433-1 Puller Bar
J 9481-A Bearing Installer
J 21352-A Support Block
J 33017 Pulley And Bearing Assembly Installer
J 33019 Bearing Staking Tool
Notice: Do not support the rotor by resting the pulley rim on a flat surface during the
bearing installation or the rotor face will be bent.
1. Place the pulley rotor on the J 21352-A in order to fully support the rotor hub during the
bearing installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092 , drive the bearing into the hub.
Document ID: 260048
Page 2 of 4
The J 9481-A applies force to the outer race of the bearing.
4. Place the J 33019 and the staking pin in the hub bore.
5. Shift the rotor and bearing assembly on the J 21352-A in order to fully support the hub under
the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold the stake pin in the guide of the J 33019 .
Important: Do not allow a metal stake to contact the outer face of the bearing in order to
prevent distortion of the outer race.
7. Using care in order to prevent injury, strike the staking pin of the J 33019 . Properly position
the stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until a stake, similar to the original stake, is formed
down to, but not touching, the bearing.
Document ID: 260048
Page 3 of 4
9. Stake 3 places 120 degrees apart.
the front head.
8433-1 .
steps:
16.1. Loosen the J 8433-3 .
front head.
Document ID: 260048
Page 4 of 4
Document ID: 260051
Page 1 of 4


Tools Required
J 8433-1 Puller Bar
location.
Document ID: 260051
Page 2 of 4
Document ID: 260051
Page 3 of 4
the front head.
8433-1 .
steps:
17.1. Loosen the J 8433-3 .
front head.
Document ID: 260051
Page 4 of 4
Document ID: 260051
Page 1 of 4


Tools Required
J 8433-1 Puller Bar
location.
Document ID: 260051
Page 2 of 4
Document ID: 260051
Page 3 of 4
the front head.
8433-1 .
steps:
17.1. Loosen the J 8433-3 .
front head.
Document ID: 260051
Page 4 of 4
Document ID: 260053
Page 1 of 3

Compressor Shaft Seal Install (V5 - Conventional

Mount)
Tools Required
J 23128-A Seal Seat Installer And Remover
J 33011 O-Ring Installer
J 34614 Shaft Seal Protector
Notice: Seals should not be re-used. Always use a new specification service seal kit. Be sure
that the seal to be installed is not scratched or damaged in any way. Make sure that the seal
is free of lint and dirt that could damage the seal surface or prevent sealing.
1. Thoroughly clean the seal O-ring groove in the front head.
2. Dip the new seal O-ring in clean 525 viscosity refrigerant oil.
Notice: Any attempt to use makeshift or inadequate service tools or equipment may result in
damage and/or improper compressor operation.
3. Assemble the O-ring onto the J 33011 .
4. Install the O-ring.
4.1. Insert the J 33011 into the compressor neck until the installer bottoms out.
Important: The top groove in the compressor neck is for the shaft seal retainer ring.
Document ID: 260053
Page 2 of 3
4.2. Lower the moveable slide of the J 33011 in order to release the O-ring into the seal Oring lower grove.
4.3. Rotate the J 33011 in order to seat the O-ring.
4.4. Remove the installer.
5. Dip the new shaft seal in clean 525 viscosity refrigerant oil.
6. Assemble the seal to the J 23128-A by turning the handle clockwise.
6.1. Ensure that the stamped steel case side of the lip seal engages with the knurled tangs
of the J 23128-A .
6.2. Ensure that the flared-out side of the lip seal faces toward the compressor.
Notice: Use care when handling the seal protector. Do not nick the seal protector. This may
damage the seal during installation. Ensure that the bottom of the seal protector is not
flared. This may damage the seal during installation.
7. Install the J 34614 on the lip seal.
8. Install the lip seal onto the shaft.
8.1. Place the J 34614 over the end of the compressor shaft.
8.2. Slide the new seal onto the shaft using a rotary motion of the J 23128-A .
8.3. Ensure that the seal makes good contact with the O-ring.
Do not dislodge the O-ring.
8.4. Disengage the J 23128-A from the seal.
8.5. Remove the J 23128-A and the J 34614 from the compressor.
Document ID: 260053
Page 3 of 3
9. Use the J 5403 in order to install the new seal retainer ring with the flat side against the seal.
10. Use the sleeve of theJ 33011 in order to press in the seal retainer ring. Ensure that the ring
11. Leak test the compressor. Refer to Compressor Leak Testing (V5 -- Conventional Mount).
12. Remove any excess oil from the shaft and the inside of the compressor neck.
13. Install the clutch plate and hub assembly. Refer to Compressor Leak Testing (V5 -Conventional Mount).
14. Install the compressor and the compressor belt. Tighten the bracket.
15. Evacuate and charge the refrigerant system using the J 39500-B .
Document ID: 260059
Page 1 of 1

Compressor Pressure Relief Valve Installation (V5 Conventional Mount)
1. Clean the valve seat area on the rear head.

2. Lubricate the O-ring of the new pressure relief valve and the O-ring assembly using new 525
viscosity refrigerant oil.
3. Install the new pressure relief valve (2).
Tighten
Tighten the valve to 9 Nm (80 lb in).
4. Perform a leak test. Refer toCompressor Leak Testing (V5 -- Conventional Mount) .
Document ID: 260063
Page 1 of 1

Compressor Leak Testing (V5 - Conventional Mount)

Tools Required
J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System
J 39893 Pressure Testing Connector
With the sealing washers in place, install the J 39893 on the rear head of the compressor.
Connect the gage charging lines and the J 39500-B .
Pressurize the suction and the high-side of the compressor using R-134a refrigerant.
With the compressor in a horizontal position, rotate the compressor shaft several turns by
hand in the operating direction.
5. Using the J 39400 , inspect for leaks at the following locations:
The pressure relief valve
1.
2.
3.
4.
The rear head switch

The front head seal
The rear head seal
The through bolt head gaskets
6.
7.
8.
9.
10.
The compressor shaft seal

Perform the measures necessary to correct any external leaks found.
Inspect for leaks again following any repair.
Recover the refrigerant.
Disconnect the hoses from the J 39893 .
Remove the J 39893 .
Document ID: 297113
Page 1 of 3

O-Ring Replacement
Removal Procedure
Tools Required
2. Place the J 38042 on the refrigerant line directly behind the female nut of the dual O-ring
joint.
Hold pressure against the nut.
3. Loosen the female nut until the seal of the dual O-ring joint is broken. This procedure aids in
the seal separation.
4. After the seal is broken, slightly tighten the female nut to facilitate the J 38042 removal.
5. Remove the female nut. Separate the connection.
Document ID: 297113
Page 2 of 3
6. Use a non-metallic tool to remove the O-rings.

The use of a non-metallic tool minimizes the chance of impairing the seal surfaces.
7. Inspect the line for kinks and dents.
8. Inspect the connection for the burrs and nicks.
Tools Required
Document ID: 297113
1.
2.
3.
4.
5.
Page 3 of 3
Lubricate the O-rings using 525 oil or mineral oil before installation.
Install the O-rings.
Oil the bore using a small amount of refrigerant oil before assembly.
Align the end forms for pilot-to-bore insertion.
Push the pilot and the bore together completely.
6. Install the female nut.

Tighten
Document ID: 297114
Page 1 of 2

Air Conditioning Compressor Bracket Replacement

Removal Procedure
1. Remove the A/C compressor. Refer to Compressor Replacement .

2. Remove the retaining bolts (1,3) from the A/C compressor mounting bracket.
3. Remove the A/C compressor mounting bracket.
Document ID: 297114
Page 2 of 2
1. Install the A/C compressor mounting bracket.

2. Install the retaining bolts (1,3) to the A/C compressor mounting bracket.
Tighten
Tighten the side bracket bolts to 100 Nm (74 lb ft).
Tighten the front bracket bolt to 50 Nm (37 lb ft).
3. Install the A/C compressor. Refer to Compressor Replacement
Document ID: 297115
Page 1 of 5

Air Conditioning Compressor Hose Replacement

Removal Procedure
Tools Required
3. Remove the upper A/C

line clip (1).
Document ID: 297115
Page 2 of 5
4. Disconnect the A/C line connection from the accumulator outlet using the J 38042 .
5. Disconnect the A/C line connection from the condenser inlet using the J 38042 .
6. Remove the A/C compressor splash shield.
7. Disconnect the electrical connector from the A/C pressure switch (4).
8. Remove the bolt (2) that attaches the A/C compressor hose assembly (3), from the rear of
the A/C compressor (1).
9. Remove the A/C compressor hose assembly (3) from the vehicle.
Tools Required
Document ID: 297115
Page 3 of 5
1. Install the A/C compressor hose assembly (3) into the vehicle.
2. Install the bolt (2) in order to attach the A/C compressor hose assembly (3) to the rear of the
A/C compressor (1).
Tighten
3. Connect the electrical connector to the A/C pressure switch (4).
4. Connect the A/C line connection to the condenser inlet.
Tighten
Tighten the condenser inlet connection to 24 Nm (18 lb ft).
5. Connect the A/C line connection to the accumulator outlet.
Tighten
Tighten the accumulator outlet connection to 24 Nm (18 lb ft).
Document ID: 297115
Page 4 of 5
6. Install the upper A/C line clip (1).

Tighten
Document ID: 297115
Page 5 of 5
Document ID: 297116
Page 1 of 4

Expansion (Orifice) Tube Replacement

Removal Procedure
Tools Required
J 26549-E Expansion Tube Remover
2. Remove the dual O-ring joint (1) of the condenser outlet using the J 38042 .
Document ID: 297116
Page 2 of 4
3. Remove the dual O-ring joint of the evaporator inlet using the J 38042 .
4. Remove the A/C line clips.
5. Remove the expansion tube from the line using the J 26549-E .
Tools Required
Document ID: 297116
Page 3 of 4
1. With the short screen toward the evaporator, install the expansion tube.
2. Position the line and install the A/C line clips.
3. Assemble the dual O-ring joints of the evaporator inlet and the condenser outlet (1).
4. Hand tighten the dual O-ring joints in order to assure correct line orientation.
Document ID: 297116
Page 4 of 4
5. Tighten the dual O-ring connections.

Tighten
Tighten the dual O-ring connections to 24 Nm (18 lb ft).
Document ID: 297117
Page 1 of 2

Air Conditioning (A/C) Refrigerant Pressure Sensor

Replacement
Removal Procedure
1. Disconnect the electrical connection from the switch (1).

The switch
The O-ring seal
1. Lubricate the O-ring using clean 525 oil or mineral oil.
Document ID: 297117
Page 2 of 2
2. Install the O-ring seal.

Tighten
Tighten the switch to 5 Nm (44 lb in).
4. Connect the electrical connection to the switch (1).
Document ID: 297118
Page 1 of 3

Air Conditioning Condenser Replacement

Removal Procedure
Tools Required
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
4. Remove the bolts (1) from the upper radiator panel.

Document ID: 297118
6.
7.
8.
9.
10.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
Page 2 of 3
inlet line from the condenser (5).

outlet line from the condenser (5).
nuts (1) and the bolts (3) from the mounting brackets (2).
upper insulators (4).
condenser (5) by tilting the radiator toward the engine.
1. Install the condenser (5) into position by tilting the radiator toward the engine.
2. Install the upper insulators (4).
Document ID: 297118
Page 3 of 3
3. Install the nuts (1) and the bolts (3) to the mounting brackets (2).
Tighten
4. Install the outline line to the condenser (5).
5. Install the inlet line to the condenser.
Tighten
Tighten the condenser connections to 24 Nm (18 lb ft).

7. Install the upper radiator panel bolts (1).
Tighten
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls.
Document ID: 297120
Page 1 of 3

Air Conditioning Accumulator Replacement

Removal Procedure
Tools Required
End.
3.
4.
5.
6.
Remove the sight shield of the rear engine.

Loosen the retaining clamp screw.
Use the J 38042 to disconnect the accumulator inlet and outlet connections.
Remove the retaining clamp screw.
Document ID: 297120
Page 2 of 3
7. Remove the accumulator (1).
Tools Required
1. Install the accumulator (1).

Document ID: 297120
Page 3 of 3
2. Install the retaining clamp screw.
Tighten
Tighten the screw to 6 Nm (53 lb in).
3. Connect and torque the accumulator inlet and outlet connections.
Tighten
Tighten the accumulator connections to 34 Nm (25 lb ft).
4.
5.
6.
7.
Install the sight shield of the rear engine.

Install the cross car brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
Document ID: 297121
Page 1 of 4

Blower Motor Resistor Replacement

Removal Procedure
Document ID: 297121
3.
4.
5.
6.
7.
8.
Page 2 of 4
Remove the center bolt from the multi use relay and fuse bracket.
Remove the positive booster cable.
Disconnect the underhood fuse blocks from the bracket.
Disconnect the relays from the bracket.
Remove the nuts which attach the multi-use relay and fuse bracket to the front of the dash.
Remove the fuse bracket.
9. Disconnect the connector (1) from the blower resistor assembly (3).
10. Remove the screws (2) which retain the blower resistor to the heater and A/C module (5).
11. Remove the blower resistor and gasket.
Document ID: 297121
Page 3 of 4
1. Install the blower resistor and gasket.

2. Install the screws (2) which retain the blower resistor to the heater and A/C module.
Tighten
3. Connect the wiring connector (1) to the blower resistor.
4. Install the nuts which attach the multi-use relay and fuse bracket to the front of the dash.
Tighten
Tighten the nuts to 3.8 Nm (34 lb in).
5. Move the fuse blocks and the relay into position. Snap the fuse blocks and the relay to the
bracket.
6. Connect the positive booster cable to the multi-use relay and fuse bracket using the center
bolt.
Tighten
Document ID: 297121
Page 4 of 4

Tighten
Document ID: 297123
Page 1 of 2

Blower Motor and Fan Replacement

Removal Procedure
End.
2. Remove the rear spark plug wires and bracket and set aside.
3.
4.
5.
6.
Disconnect the electrical connector (5) from the blower motor (2).
Remove the cooling tube (4) from the blower motor (2).
Remove the screws (3) that attach the blower motor (2) to the blower module assembly (1).
Remove the blower motor (2).
Document ID: 297123
Page 2 of 2
1. Install the blower motor (2).

2. Install the screws (3) to the blower motor (2).
Tighten
3.
4.
5.
6.
Install the cooling tube (4) to the blower motor (2).

Connect the electrical connector (5) to the blower motor (2).
Install the rear spark plug wires and bracket.
Install the cross car support brace. Refer to Cross Vehicle Brace Replacement in Body Front
End.
Document ID: 297125
Page 1 of 4

HVAC Module Assembly Replacement

Removal Procedure
Tools Required
J 37097-A MUBEA Hose Clamp Pliers
End.
Gauges and Console.
5. Disconnect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness
6. Remove the evaporator. Refer to Evaporator Core Replacement .
7. Remove the heater hoses from the heater core using the J 37097-A .
8. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power
Steering Systems.
9. Remove the air distributor. Refer to Air Distributor Duct Replacement .
10. Remove the aspirator adapter (C68 and CJ2).
11. Remove the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
Document ID: 297125
Page 2 of 4
12. Remove the bolts (5) that attach the heater and A/C module assembly (3) to the front of the
dash (4).
13. Remove the bolts (1) and the studs (2) that attach the heater and A/C assembly (3) to the
front of the dash (4).
15. Remove the remainder of the heater and A/C module assembly (3).
16. If replacing the heater and A/C module assembly (3), transfer the heater core to a new
module assembly (3).
Document ID: 297125
Page 3 of 4
1. Install the heater and A/C module assembly (3) (partial).

2. Install the bolts (1) and the studs (2) to attach the heater and A/C module assembly (3) to
the rear of the dash (4).
Reposition the insulation as needed.
Tighten
Tighten the bolts and the studs to 5 Nm (44 lb in).
3. Install the bolts (5) to attach the heater and A/C module assembly (3) to the front of the
dash (4).
Document ID: 297125
Page 4 of 4
Tighten
4.
5.
6.
7.
8.
Install the heater and A/C programmer (C68 and CJ2). Refer to Programmer Replacement .
Install the aspirator adapter (C68 and CJ2).
Install the air distributor. Refer to Air Distributor Duct Replacement .
Install the vacuum source input to the right side of the air distributor.
Install the power steering pump. Refer to Power Steering Pump Replacement in Power
Steering Systems.
9. Install the heater hoses to the heater core using the J 37097-A .
10. Install the evaporator. Refer to Evaporator Core Replacement .
11. Connect the right bank spark plug wires and bracket. Refer to Spark Plug Wire Harness
Gauges and Console.
13. Install the cross car brace support. Refer to Cross Vehicle Brace Replacement in Body Front
End.
14. Fill the cooling system. Refer to Cooling System Draining and Filling .
Document ID: 297126
Page 1 of 6

Air Conditioning Evaporator Core Replacement

Removal Procedure
Tools Required
End.

4. Remove the accumulator. Refer to Accumulator Replacement .
Document ID: 297126
Page 2 of 6
5. Remove the positive booster cable from the multi-use relay center.
6. Position the under hood fuse block out of the way.
7.
8.
9.
10.
11.
12.
Remove the evaporator tube from the evaporator.

Remove the wire harness clip from the HVAC module.
Remove the accumulator bracket.
Remove the heat shield of the HVAC module.
Following the cut line, cut the top side of the HVAC module cover.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Document ID: 297126
13.
14.
15.
16.
17.
Page 3 of 6
Following the cut line, cut the bottom side of the HVAC module cover.
Lower the vehicle.
Remove the fuel line clip from the HVAC module.
Remove the insulator from the module.
Remove the bolt that attaches the heater and A/C module assembly to the inside of the
vehicle.
Remove the blower module from the HVAC module assembly.
18. Remove the evaporator core.
Document ID: 297126
Page 4 of 6
1. Install the evaporator core.

2. Install the blower module to the HVAC module assembly.
Tighten
4. Install the bolt to attach the heater and A/C module assembly to the inside of the vehicle.
Tighten
5.
6.
7.
8.
Install
Install
Install
Install
the
the
the
the
insulator to the module.

fuel line clip to the HVAC module.
HVAC module heat shield.
bolts.
Tighten
9. Install the accumulator bracket.
10. Install the screws.
Document ID: 297126
Page 5 of 6
Tighten
11. Install the wire harness clip to the HVAC module.
12. Install the evaporator tube to the evaporator.

Tighten
Tighten the evaporator tube connection to 24 Nm (18 lb ft).
13. Reposition the under hood fuse block to the original position.
14. Install the booster cable from the multi-use relay center.
15. Install the accumulator. Refer to Accumulator Replacement .
Document ID: 297126
Page 6 of 6
17. Install the cross car support. Refer to Cross Vehicle Brace Replacement in Body Front End.
Document ID: 297127
Page 1 of 4

Heater Core Replacement

Removal Procedure
Tools Required
J 37097-A Hose Clamp Pliers
1. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Remove the heater hoses (2) from the heater core using the J 37097-A .
5. Remove the temperature valve actuator. Refer to Temperature Actuator Replacement .
6. Remove the HVAC programmer (C68). Refer to Programmer Replacement
Document ID: 297127
7.
8.
9.
10.
Remove
Remove
Remove
Remove
the
the
the
the
heater
heater
heater
heater
Page 2 of 4
core cover retaining screws.

core cover.
core retaining screws.
core.
1. Install the heater core into the vehicle.
Tighten
Document ID: 297127
Page 3 of 4
3. Install the heater core cover.

Tighten
5. Install the HVAC programmer (C68). Refer to Programmer Replacement
6. Install the temperature valve actuator. Refer to Temperature Actuator Replacement .
Document ID: 297127
Page 4 of 4
9. Install the heater hoses (2) to the heater core using the J 37097-A .
10. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
Document ID: 401694
Page 1 of 3

Control Assembly Replacement (Buick)

Removal Procedure

4. Disconnect the electrical connectors and remove the HVAC control assembly.
Document ID: 401694
Page 2 of 3
1. Connect the electrical connectors to the HVAC control assembly.
2. Install the HVAC control assembly into the instrument panel.

Document ID: 401694
Page 3 of 3

Tighten
Document ID: 401695
Page 1 of 2

Control Assembly Replacement (Oldsmobile)

Removal Procedure
1. Remove the I/P cluster trim plate. Refer to Instrument Panel Accessory Trim Plate
2. Gently pry the assembly out from the instrument panel.
3. Disconnect the electrical and vacuum connectors.

4. Remove the HVAC control assembly.
Document ID: 401695
Page 2 of 2
1. Connect the vacuum and electrical connectors to the HVAC control assembly.
2. Install the HVAC control assembly into the instrument panel by snapping into place.
3. Install the I/P cluster trim plate. Refer to Instrument Panel Accessory Trim Plate Replacement
Document ID: 401706
Page 1 of 3

Control Assembly Replacement (Pontiac)

1. Remove the I/P accessory trim plate. Refer to Instrument Cluster Trim Panel Replacement in

4. Disconnect the electrical and vacuum connectors.

5. Remove the HVAC control assembly.
Document ID: 401706
Page 2 of 3
1. Connect the electrical and vacuum connectors to the HVAC control assembly.
2. Install the HVAC control assembly into the instrument panel by snapping into place.
Document ID: 401706
Page 3 of 3
Tighten
4. Install the I/P accessory trim plate. Refer to Instrument Cluster Trim Panel Replacement in
Document ID: 297128
Page 1 of 2

Air Inlet Actuator Replacement

Removal Procedure
1. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement Left Side in Instrument Panel, Gauges and Console.
2. Disconnect the vacuum hose from the outside air/recirculation actuator (1).
3. Unclip the outside air/recirculation actuator (1) from the air inlet.
4. Disengage the outside air/recirculation actuator (1) from the valve.
Document ID: 297128
1.
2.
3.
4.
Page 2 of 2
Engage the outside air/recirculation actuator (1) to the valve.

Clip the outside air/recirculation actuator (1) to the air inlet.
Connect the vacuum hose to the outside air/recirculation actuator (1).
Install the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges and Console.
Document ID: 297129
Page 1 of 2

Temperature Actuator Replacement

Removal Procedure
1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal in
out of the valve.
3. Disconnect the electrical connector (3) from the A/C temperature valve actuator (4).
4. Remove the screws (2) which retain the actuator to the heater and A/C module (5).
5. Remove the actuator.
Document ID: 297129
Page 2 of 2
1. Install the A/C temperature and valve actuator (4) to the heater and A/C module (5).
Tighten
3. Connect the electrical connector (3) to the A/C temperature valve actuator.
Important: Adjust the temperature valve link rod prior to installation. Refer to Temperature
Valve Link Adjustment .
4. Install the temperature valve link rod (1) to the temperature valve, by snapping the rod into
place.
5. Install the instrument panel assembly. Refer to Instrument Panel Assembly Removal in
Document ID: 297130
Page 1 of 2

Defroster Valve Actuator Replacement

Removal Procedure
2. Unclip the defrost-A/C actuator (3) from the air inlet.

3. Disengage the defrost-A/C actuator (3) from the valve.
Document ID: 297130
Page 2 of 2
1. Engage the defrost-A/C actuator (3) to the valve.

2. Clip the defrost-A/C actuator (3) to the air inlet.
Document ID: 297131
Page 1 of 2

Heater/Bi-Level Actuator Replacement

Removal Procedure
1. Remove the air distributor assembly. Refer to Air Distributor Duct Replacement .
2. Remove the clip and the screws that fasten the 2 halves of the air distributor assembly:
Separate the air distributor assembly.

In order to disconnect the vacuum actuator (5) from the air distributor assembly, unclip
and disengage the vacuum actuator (5) from the valve.
Document ID: 297131
Page 2 of 2
1. In order to connect the vacuum actuator (5) to the air distributor assembly, clip and engage
the vacuum actuator to the valve.
2. Fasten the 2 halves of the air distributor assembly.
Tighten
Document ID: 297132
Page 1 of 1

Temperature Valve Link Adjustment
out of the valve.
2. Start the vehicle. Make the following settings:
Set the fan to position IIII (HIGH).
Set the temperature to full hot.
3. Allow 45 seconds minimum for the A/C temperature valve actuator (4) to move to the full hot
position.
5. Snap the temperature valve link rod into the temperature valve.
Document ID: 297134
Page 1 of 2

Air Distributor Duct Replacement

Removal Procedure
Guages and Console.
2. Remove the screws (1) from the center air distributor (2).
3. Remove the center air distributor (2).
Document ID: 297134
Page 2 of 2
1. Install the center air distributor (2).

Tighten
Guages and Console.
Document ID: 297135
Page 1 of 2

Crosscar Air Outlet Replacement

Removal Procedure
Gauges and Console.
2. Remove the duct mounting screws (1).

3. Remove the duct (2).
Document ID: 297135
Page 2 of 2
1. Install the duct (2).

2. Install the duct mounting screws (1).
Tighten
3. Install the side window defogger adapters.
Gauges and Console.
Document ID: 297137
Page 1 of 2

Vacuum Tank Replacement

Removal Procedure
1. Turn the front wheels to the right.
3. Remove 2 vacuum tank mounting screws.

4. Remove the vacuum hose from the tank.
5. Remove the vacuum tank from the vehicle.
Document ID: 297137
Page 2 of 2
1. Install the vacuum tank.

2. Install the 2 screws to secure the vacuum tank.
Tighten
3. Install the vacuum hose to the tank.
Document ID: 297139
Page 1 of 2

Vacuum Electrical Solenoid Replacement

Removal Procedure
1. Perform the following steps in order to swing down the IP compartment:

1.1. Pull the IP compartment rearward.
2.
3.
4.
5.
1.2. Disengage the swing stops.

Disconnect the vacuum harness connector (3) from the solenoid (1).
Disconnect the electrical connector (2) from the solenoid (1).
Remove the screws (4) from the solenoid (1).
Remove the solenoid (1) from the heater and A/C module (5).
Document ID: 297139
Page 2 of 2
1. Install the solenoid (1) to the heater and A/C module (5).
2. Install the screws (4) to the solenoid (1).
Tighten
3. Connect the electrical connector (2) to the solenoid (1).
4. Connect the vacuum harness connector (3) to the solenoid (1).
5. Push forward on the IP compartment in order to install the IP compartment.
Document ID: 297143
Page 1 of 2

Air Inlet Assembly Replacement

Removal Procedure
2. Remove the bolts (2) that attach the air inlet (3) to the dash panel (1) and to the front of the
dash.
3. Reposition the insulation as needed to remove the air inlet assembly (3).
Document ID: 297143
Page 2 of 2
1. Position the air inlet (3) in the vehicle.

3. Install the bolts (2) to attach the air inlet (3) to the dash panel (1) and to the front of the
dash.
Refer to the illustration for the proper tightening sequence.
Tighten
Document ID: 388520
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Brakes | Hydraulic Brakes |

Specification
Application
Metric
English
21 Nm
15 lb ft
9 Nm
80 lb in
Brake Hose to Caliper
45 Nm
33 lb ft
Brake Pedal Bracket Attaching Bolt
24 Nm
18 lb ft
Brake Pipe Fitting (Tube Nut)
15 Nm
11 lb ft
Brake Pipe to Proportioner
15 Nm
11 lb ft
Caliper Bleeder Valve
13 Nm
115 lb in
Master Cylinder attaching Nuts
27 Nm
20 lb ft
Proportioner Valve to Brake Pipe Fitting
15 Nm
11 lb ft
Wheel Cylinder Bleeder Valve
10 Nm
88 lb in
Booster to Pedal Bracket Nuts

Bracket to Rear Drum Plate Bolt
2/7/2011
Document ID: 388522
Page 1 of 1
Specification
Application
Metric
English
57.00 mm
2.25 in
Brake Pedal Travel

Brake pedal travel maximum with 445 N (100 lb) force applied to
the pedal with ignition OFF and vacuum or hydraulic assist
depleded.
Brake Drums
l
Discard Diameter*(See note at the bottom).
226.30 mm
8.909 in
Inside Diameter
225.12 mm
8.863 in
Maximum Refinish Diameter
226.57 mm
8.920 in
Runout
0.15 mm
0.006 in
Brake Rotors
l
Discard Thickness*(See Note at the bottom)
30.70 mm
1.209 in
Front Caliper Bore Diameter
63.50 mm
2.50 in
Lateral Runout
0.060 mm
0.002 in
Master Cylinder Bore Diameter
25.40 mm
1.000 in
Minimum Thickness After Refinish
31.08 mm
1.224 in
Minimum Vacuum at Power Booster
--
14 in Hg
Rotor Thickness (Maximum)
32.00 mm
1.260 in
Thickness Variation
0.013 mm
0.0005 in
Wheel Cylinder Bore Diameter
23.80 mm
0.937 in
All brake drums and rotors have a discard dimension cast into them. This is a wear
dimension and not a refinish dimension. any drum or rotor which does not meet the
specification should be replaced.
2/7/2011
Document ID: 219856
Page 1 of 1
Brake Warning System Schematics (Buick)

Cell 41
2/7/2011
Document ID: 219859
Page 1 of 1
Brake Warning System Schematics (Oldsmobile)

Cell 41
2/7/2011
Document ID: 219861
Page 1 of 1
Brake Warning System Schematics (Pontiac)

Cell 41
2/7/2011
Document ID: 232569
Page 1 of 1
Brake Warning System Components

(2) Brake Fluid Level Switch
(3) Master Cylinder Reservoir
(4) Not present
(5) Windshield Wiper Motor
2/7/2011
Document ID: 232572
Page 1 of 1
Brake Warning System Components
(1) Park Brake Assembly

(2) Park Brake Switch
2/7/2011
Document ID: 232872
Page 1 of 1
Hydraulic Brake Connector End Views

Brake Fluid Level Switch
12162195
Pin
Wire Color
Circuit No.
TAN/WHT
33
BLK
1250
Function
Brake Fluid Level Signal
Ground
2/7/2011
Document ID: 388529
Page 1 of 1
Master Cylinder Reservoir Filling

Notice: When filling the master cylinder, use only Delco Supreme 11, GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT 3 brake fluid. Do not use a container which has been
used for petroleum based fluids, or a container which is wet with water. Petroleum based fluids will
cause swelling and distortion of rubber parts in the hydraulic brake system, and water will mix with
brake fluid, lowering the boiling point. Keep all fluid containers capped to prevent contamination.
Keep the master cylinder brake fluid reservoir properly filled to ensure adequate reserve and to
prevent air and moisture from entering the hydraulic system. However, adding brake fluid is not
usually necessary unless the brake system has a leak, indicated by the BRAKE warning lamp
coming on due to low brake fluid, or the system is being serviced. Because of fluid expansion due
to heat absorbed from the brakes and the engine, the reservoir must not be overfilled.
The brake fluid level will become lower with brake lining wear, and should return to about the full
level when new linings are installed. If brake fluid has been added to the reservoir prior to lining
change, the resultant level may be over full.
To top up or fill the reservoir, thoroughly clean around the reservoir cap before removing it to
avoid getting dirt into the reservoir. Then, remove the cap with a diaphragm.
Add fluid as needed to bring the level to the full mark.
Use only Delco Supreme 11 (GM P/N 12377967) Brake Fluid, or equivalent DOT-3 brake fluid.
2/7/2011
Document ID: 388542
Page 1 of 2
Master Cylinder Replacement

Removal Procedure
1.
2.
3.
4.
5.
Disconnect the electrical connector from the fluid level sensor (2).
Drain the brake fluid from the master cylinder reservoir.
Remove the brake pipes from the master cylinder (4).
Plug the open pipes to prevent fluid loss and contamination.
Remove the two attaching nuts (3).
6. Remove the master cylinder (5).

7. Remove the reservoir, if it is to be used on the replacement master cylinder. Refer to Master
Cylinder Reservoir Replacement .
1. Install the reservoir onto the master cylinder, as needed. Refer to Master Cylinder Reservoir
Replacement .
2/7/2011
Document ID: 388542
Page 2 of 2
2. Install the master cylinder (5) onto the power booster (1).
3. Install the attaching nuts (3).
Tighten
4. Install the brake pipes (4).
Tighten
Tighten the brake pipe fittings to 15 Nm (11 lb ft).
5. Fill the master cylinder reservoir to the full level mark using only Delco Supreme II (GM P/N
12377967) Brake Fluid, or equivalent DOT-3 brake fluid.
6. Connect the electrical connector to the fluid level sensor (2).
7. Bleed the hydraulic system. Refer to Hydraulic Brake System Bleeding .
8. Recheck the fluid level in the reservoir.
2/7/2011
Document ID: 388545
Page 1 of 1
Master Cylinder Bench Bleeding

Bench bleed the master cylinder before installation on the vehicle. Bench bleeding removes air
from the master cylinder. Bench bleeding reduces the time required in order to bleed the brake
hydraulic system after installation.
1. Plug the outlet ports. Mount the master cylinder in a vise with the front end slightly down.
2. Fill the master cylinder reservoir with clean brake fluid.
3. Stroke the primary piston about 25 mm (1 in) several times using a smooth round-end tool.
The primary piston will not travel the full 25 mm (1 in) stroke as air bleeds from the master
cylinder.
4. Reposition the master cylinder in the vise with the front end tilted slightly up.
5. Stroke the primary piston about 25 mm (1 in) several times again.
6. Reposition the master cylinder in the vise. The master cylinder should be level.
7. Loosen the plugs in the outlet ports one at a time. Then push the piston into the bore in
order to force the air from the cylinder.
8. Tighten the plug(s) before allowing the piston to return to its original position. This prevents
air from being drawn back into the cylinder.
9. Fill the master cylinder reservoir with clean brake fluid.
10. Follow normal bleeding procedures after installing the master cylinder. Refer to Hydraulic
Brake System Bleeding .
2/7/2011
Document ID: 388557
Page 1 of 1
Brake Fluid Level Indicator Switch Replacement

Removal Procedure
1. Remove the electrical connector from the fluid level sensor switch.
2. Drain the brake fluid.
3. Disconnect the fluid level sensor switch. Use the needle nose pliers to compress the switch
locking tabs and pull out of the fluid reservoir.
1. Snap the fluid level sensor switch into place.
2. Install the electrical connector.
3. Refill the brake fluid. Refer to Master Cylinder Reservoir Filling .
2/7/2011
Document ID: 388532
Page 1 of 2
Master Cylinder Reservoir Replacement

Removing and installing the cap is straightforward. Be sure to thoroughly clean around the
reservoir cap before removing it to avoid getting dirt into the reservoir. Then remove the cap with
a diaphragm.
The fluid level sensor is serviced only by replacing the reservoir.
Removal Procedure
1. Disconnect the electrical connector from the fluid level sensor.
2. Drain the brake fluid from the master cylinder reservoir.
3. Tap back pins until clear of reservoir. Be careful not to damage the reservoir or the master
cylinder. If needed, loosen or remove the strut cross bar for access.
4. Remove the reservoir.
5. Remove the seals.
6. Inspect the reservoir for cracks or deformities. If found, replace the reservoir.
7. Clean the reservoir with clean denatured alcohol. Dry with unlubricated compressed air.
1. Lubricate the new seals and reservoir bayonets with clean brake fluid.
2. Install the seals, making sure they are fully seated.
2/7/2011
Document ID: 388532
Page 2 of 2
3. Install the reservoir onto the master cylinder by pressing straight down by hand until the pin
holes are aligned.
4. Tap in the pins to retain the reservoir. Be careful not to damage the reservoir or master
cylinder. If the strut cross bar had been loosened or removed, reinstall it.
5. Fill the master cylinder reservoir to the full level mark using only Delco Supreme II (GM P/N
12377967) Brake Fluid, or equivalent DOT-3 brake fluid, as specified in Maintenance and
Lubrication.
6. Connect the electrical connector to the fluid level sensor.
7. Bleed the hydraulic system. Refer to Hydraulic Brake System Bleeding .
8. Recheck the fluid level in the reservoir.
2/7/2011
Document ID: 388537
Page 1 of 1
Master Cylinder Cover/Caps Replacement

Removing and installing the cap is straightforward. Be sure to thoroughly clean around the
reservoir cap before removing it to avoid getting dirt into the reservoir. Then, remove the cap with
diaphragm.
The fluid level sensor is serviced only by replacing the reservoir.
2/7/2011
Document ID: 388559
Page 1 of 3
Brake Pedal Replacement

Removal Procedure
1. Disable the SIR system. Refer to Disabling the SIR System in (SIR) System.
2. Remove the instrument panel assembly. Refer to Knee Bolster Replacement in Instrumental
Panel, Gauges and Console.
3. Disconnect the electrical connectors from the switch.
4. Remove the two bolts (7 and 6).
5. Remove the pushrod

(3)
from
the pushrod
pin (2). All rights reserved.
2011
General
Motors Corporation.
2/7/2011
Document ID: 388559
Page 2 of 3
6. Remove the barrier.

7. Remove the four nuts from the booster studs.
8. Remove the brake pedal assembly (5).
1. Install the brake pedal assembly (5) onto the booster studs.
2. Apply lubricant, GM P/N 9985146 or equivalent, to the pushrod pin (2).
3. Hand start the two bolts (7 and 6) through the brake pedal assembly into the cowl bar and
steering column support.
4. Install the pushrod (3) onto the pushrod pin (8).
5. Secure the pushrod with a spacer and a retainer.
2/7/2011
Document ID: 388559
Page 3 of 3
6. Install the four nuts onto the booster studs.

Tighten
Tighten the nuts to 21 Nm(15 lb ft).
7. Install the barrier (4) onto the brake pedal assembly.
8. Align with the booster studs.
9. Tighten the bolt (6) first, and then bolt (7).
Tighten
Tighten the bolts to 24 Nm(18 lb ft).
10. Connect the electrical connectors to the switch.
11. Install the instrument panel assembly. Refer to Knee Bolster Replacement in Instrumental
12. Enable the SIR system. Refer to Enabling the SIR System in (SIR).
2/7/2011
Document ID: 388699
Page 1 of 1
Brake Pipe Replacement

Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any
other pipe is not recommended and may cause brake system failure. Carefully route and retain
replacement brake pipes. Always use the correct fasteners and the original location for replacement
brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes
and cause brake system failure.
Tools Required
J 29803-A ISO Flaring Tool
Important: This vehicle uses only ISO flares on the brake pipe connections. Do not attempt to use
single or double lap flares when replacing the brake pipes.
2/7/2011
Document ID: 388701
Page 1 of 1
ISO Flares Replacement

1. Obtain the recommended tubing and steel fitting nuts of correct size. (Outside diameter of
the tubing is used to specify size.)
2. Cut the tubing to length. You can determine the length needed by measuring the old pipe
using a string and adding 3.2 mm (1/8 in) for each ISO flare.
3. Install the fittings on the tubing before starting flare.
4. Chamfer the inside and the outside diameter of tubing with the deburring tool. Then flare the
tubing ends using an ISO flaring tool, such as J 29803-A ISO Flaring Kit. Follow the
instructions included with the tool.
5. Carefully bend the tubing to match the old pipe. Clearance of 19 mm (3/4 in) must be
maintained between the pipe and all moving or vibrating parts.
2/7/2011
Document ID: 388705
Page 1 of 1
Brake Hose Inspection

Hydraulic brake hoses should be inspected at least twice a year. Check the brake hoses for the
following:
Road hazard damage
Cracks and chafing of outer cover
Leaks and blisters
Proper routing and mounting
If you find any of these conditions, adjust or replace the hose. A brake hose which rubs on other
components will wear and eventually fail.
A light and mirror can be helpful for thorough inspections.
Important: Never allow the brake components, such as calipers, to hang from the flexible hoses,
as damage to the hoses may occur. Some brake hoses have protective rings or covers to prevent
direct contact with other chassis parts. Besides causing possible structural damage to the hose,
excessive tension could cause the hose rings to move out of their proper locations.
2/7/2011
Document ID: 388706
Page 1 of 1
Hydraulic Brake System Bleeding

Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can
cause the loss of brakes with possible personal injury.
Whenever air gets into the brake hydraulic system, you must bleed the system to remove it. You
might have to bleed the hydraulic system at all four wheel positions if air has entered the system
due to low fluid level, or from brake pipes having been disconnected at the master cylinder. If a
brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If pipes
are disconnected at any fitting located between the master cylinder and the wheels, then the brake
system served by the disconnected pipe must be bled. Refer to hydraulic system bleeding.
2/7/2011
Document ID: 388707
Page 1 of 1
Hydraulic Brake System Flushing

The entire hydraulic system should be thoroughly flushed with clean brake fluid if there is any
doubt as to the grade of fluid in the system, or if fluid has been used that contains the slightest
trace of mineral oil.
All rubber parts which have been subjected to the contaminated fluid must be replaced before
flushing the system.
Flushing is performed at each wheel in the same way that bleeding is done, except that new fluid
must be forced through the system until it emerges clear in color. About one quart of new fluid is
needed to flush the system.
After completing the flushing operation at all bleeder valves, check that the master cylinder is filled
to the correct level. Refer to hydraulic system flushing.
2/7/2011
Document ID: 388710
Page 1 of 3
Power Vacuum Brake Booster Replacement

Removal Procedure
Important: The booster can be removed from the vehicle without removing or disconnecting
the master cylinder. However, if both the booster and master cylinder are to be removed,
remove the master cylinder first; refer to Master Cylinder Replacement in Hydraulic Brakes.
Disconnect the booster vacuum hose (1) from the vacuum check valve (2).
1. Remove the master cylinder attaching nuts (6).

2. Remove the master cylinder (7) from the booster (2).
3. Move the master cylinder (7) forward just enough to clear the studs on the booster. This will
flex the brake pipes slightly, it's important to be careful not to bend or distort the pipes.
4. Remove the acoustical barrier from the booster studs (under I/P).
5. Remove the booster attaching nuts (4).
6. Remove the booster pushrod from the brake pedal.
7. Tilt the entire booster slightly to work the pushrod off the pedal clevis pin without putting
undue side pressure on the pushrod.
8. Remove the booster from the vehicle.
9. Remove the gasket.
1. Connect the gasket to the booster.
2/7/2011
Document ID: 388710
Page 2 of 3
2. Connect the booster (2) to the vehicle.

3. Connect the booster pushrod to the brake pedal.
4. Tilt the entire booster slightly to work the pushrod onto the pedal clevis pin without putting
undue side pressure on the pushrod.
5. Install the booster attaching nuts (4).
Tighten
Tighten the attaching nuts to 21 Nm 15 lb ft).
6. Install the acoustical barrier onto the booster studs (under I/P).
7. Connect the master cylinder (7) to the booster (2).
8. Install the master cylinder attaching nuts (6).
Tighten
Tighten the attaching nuts to 27 Nm 20 lb ft).
2/7/2011
Document ID: 388710
Page 3 of 3
9. Connect the booster vacuum hose (1) to the vacuum check valve (2).
2/7/2011
Document ID: 388712
Page 1 of 2
Stop Lamp Switch Replacement

Removal Procedure
1. Remove the I/P sound insulators, as needed for access.

2. Remove the lower switch, twist counterclockwise to unlock and pull out of the retainer.
3. Remove the electrical connectors from the switch.
2/7/2011
Document ID: 388712
Page 2 of 2
1. Slide the switch (with all the connections made) into the retainer.
2. Press the switch in until the switch plunger is fully depressed into the switch barrel.
3. Twist the switch clockwise until the travel stop has been reached (approximately 60
degrees). With the switch fully locked, the electrical connector will face the 3 o'clock position.
2/7/2011
Document ID: 388714
Page 1 of 1
Stop Lamp Switch Adjustment

The Brake pedal switches are self adjusting when installed properly in the fully locked position. The
twist lock type switches do not need any further adjustment.
2/7/2011
Document ID: 299505
Page 1 of 1
Instrument Panel, Gauges, and Console | Specifications | Document ID: 299505
Fastener Tightening Specifications (Buick)

Specification
Application
Metric
English
Cluster Lens To Cluster Assembly Fasteners
1.9 Nm
17 lb in
Instrument Panel Cluster to IP Assemlby Fasteners
1.5 Nm
14 lb in
Instrument Panel Assembly Center Bracket Fasteners
10 Nm
89 lb in
Instrument Panel Assembly Lower Front Fasteners
2 Nm
18 lb in
Instrument Panel Assembly Upper Fasteners
2 Nm
18 lb in
Instrument Panel Compartment to Instrument Panel Fasteners
1.9 Nm
17 lb in
Instrument Panel Trim Plate Fasteners
1.9 Nm
17 lb in
Instrument Panel Wiring Interconnect Fasteners
10 Nm
89 lb in
Knee Bolster Fasteners
10 Nm
89 lb in
Sound Insulator to Dash Panel Fasteners
1.9 Nm
17 lb in
Steering Column Support Bracket Brace Fasteners
8.5 Nm
75 lb in
Upper Trim Plate Fasteners
1.9 Nm
17 lb in
tomsn048@gmail.com
2/7/2011
Document ID: 412141
Page 1 of 1
Instrument Panel, Gauges, and Console | Specifications | Document ID: 412141
Scan Tool Data List

Scan Tool Parameter
Data List
Units Displayed
Typical Data Value
Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop

Brake Fluid Level
Inputs
OK/Low
OK
Right Turn Signal Switch
Inputs
On/Off
Off
Left Turn Signal Switch
Inputs
On/Off
Off
Park Brake Switch
Inputs
On/Off
Off
Washer Fluid Level
Inputs
OK/Low
OK
Oil Level
Inputs
OK/Low
OK
Trans Range A
Inputs
LO/HI
LO
Trans Range B
Inputs
LO/HI
HI
Trans Range C
Inputs
LO/HI
HI
Trans Range P
Inputs
LO/HI
LO
Oil Pressure Switch
Inputs
Open/Closed
Open
Low Coolant Level
Inputs
OK/Low
OK
DIM Level
Gauges
Volts
--
DIM Reference
Gauges
Volts
--
Vehicle Speed
Gauges
km/h/MPH
Engine Speed
Gauges
RPM
Battery Voltage
Gauges
Volts
13.0
Fuel Level
Gauges
liter/gal
--
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2/7/2011
Document ID: 344432
Page 1 of 1
Instrument Panel, Gauges, and Console | Schematic and Routing Diagrams | Document ID: 344432
Cell 80: IP Fuse Block
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2/7/2011
Document ID: 344436
Page 1 of 1
Cell 80: Instrument Cluster
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2/7/2011
Document ID: 344439
Page 1 of 1
Cell 80: Indicators
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2/7/2011
Document ID: 344445
Page 1 of 1
Cell 80: Indicators # 2
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2/7/2011
Document ID: 344449
Page 1 of 1
Cell 80: Fuel Sender
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2/7/2011
Document ID: 344472
Page 1 of 1
Cell 81:Gauges
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2/7/2011
Document ID: 344474
Page 1 of 1
Cell 81: Fuel Tank Unit
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2/7/2011
Document ID: 344477
Page 1 of 1
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2/7/2011
Document ID: 344480
Page 1 of 1
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2/7/2011
Document ID: 344482
Page 1 of 1
Cell 81: Remote Indicator Bank
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2/7/2011
Document ID: 344485
Page 1 of 1
Cell 81: IP Fuse Block
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2/7/2011
Document ID: 1539397
Page 1 of 1
HUD Schematic
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2/7/2011
Document ID: 343279
Page 1 of 1
Instrument Panel, Gauges, and Console | Component Locator | Document ID: 343279
Right Hand Rear of the Engine
(1) Engine Oil Pressure Switch

(2) G101
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2/7/2011
Document ID: 400607
Page 1 of 1
Passenger Compartment, Below the Instrument Cluster
(1) Head-Up Display (HUD) Control (Pontiac w/UV6)
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2/7/2011
Document ID: 343055
Page 1 of 1
Left Hand Front of the Engine Compartment
(1) Hood Ajar Switch
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2/7/2011
Document ID: 400526
Page 1 of 1

Others Similar

(2) Cigar Lighter
(5) Radio
(7) Fog Lamp Switch
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2/7/2011
Document ID: 400524
Page 1 of 1
Passenger Compartment, On the Rear Door
(1) LH Rear Power Window Switch (RH Similar)

(2) LH Rear Door Courtesy Lamp (RH Similar)
(3) LH Rear Door Warning Lamp (RH Similar)
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2/7/2011
Document ID: 343334
Page 1 of 1
Under the Left Hand of the Instrument Panel
(1) IP Fuse Block

(2) LH IP Sound Insulator
(3) Turn Signal Flasher
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2/7/2011
Document ID: 343072
Page 1 of 1
Engine Compartment, Near the Left Strut Tower
(1) Windshield Washer Pump

(2) Windshield Washer Solvent Reservoir
(3) S128
(4) S124
(5) Windshield Washer Solvent Level Switch
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2/7/2011
Document ID: 400464
Page 1 of 1
Rear Compartment, Under the Rear Package Shelf
(1) Electronic Compass Module
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2/7/2011
Document ID: 408278
Page 1 of 1
Audible Warnings Component Views

Top of the Steering Column
(1) Turn Hazard Switch (Hidden)

(2) Multifuntion Lever
(3) Windshield Wiper Switch
(4) Ignition Switch (Hidden)
(5) Ignition Lock Cylinder
tomsn048@gmail.com
2/7/2011
Document ID: 359679
Page 1 of 15
Instrument Cluster and HUD Connector End Views

Table 1:
Head Up Display Module (Pontiac)
Table 2:
Instrument Cluster Connector - Buick with U23
Table 3:
Instrument Panel Gauges Connector - Buick with UB3
Table 4:
Remote Indicator Back Connector - Buick with UB3
Table 5:
Instrument Cluster C1 (Oldsmobile w/ UH8)
Table 6:
Instrument Cluster Connector C2 - Oldsmobile with UH8
Table 7:
Instrument Cluster Connector - Pontiac with UB3
Table 8:
Instrument Cluster Connector C1 - Pontiac with U50/U2F
Table 9:
Table 10: Transmission Position Decoder Module -- Pontiac

Table 11: Transmission Position Decoder Module -- Oldsmobile
Table 12: Windshield Washer Solvent Level Switch
Table 13: Electronic Compass Module
Table 14: Engine Oil Pressure Switch
Table 15: Head-up Display (HUD) Control
Table 16: Head-up Display (HUD) Adjuster Motor
Table 17: Hood Ajar Switch
Table 18: LH Front Seat Belt Switch
Head Up Display Module (Pontiac)
12059197
F Micro - Pack 100 Series(LT GRY)
Pin
Wire Color
Circuit No.
--
--
Not Used
YEL
32
Fused Output-Instrument Panel Lamp
WHT
717
DK GRN/WHT
tomsn048@gmail.com
1194
Function
Illuminated Display Signal

Low Fuel Level Signal
2/7/2011
Document ID: 359679
Page 2 of 15
Turn Signal Lamp Feed-Left Front
LT BLU
14
BRN
1675
Check Gages Signal
BLK
1450
Ground
DK GRN/WHT
817
LT GRN
11
High Beam Headlamp Feed
10
DK BLU
15
Turn Signal Lamp Feed-Right Front
11
BRN
1141
12
BLK/WHT
251
Fused Output-IGN
Ground
Instrument Cluster Connector - Buick with U23
Connector Part
Information
12065804
Pin
Wire Color
Circuit
No.
A1
DK BLU
15
Turn Signal Lamp Feed - RH Front
A2
TAN/WHT
33
Brake Warning Indicator Lamp Output
A3
BRN/WHT
419
Check Engine Indicator Lamp Output
A4
DK GRN
264
Security Indicator Lamp Feed
A5
ORN
40
A6
LT GRN/BLK
875
A7
WHT
85
Cruise Indicator Lamp Output
A8
TAN
31
Oil Pressure Indicator Lamp Output
A9
BRN
25
Volts Indicator Lamp Output
A10
DK GRN
35
Coolant Temperature (TEMP) Indicator Lamp

Output
A11
BRN
358
Air Bag Indicator Lamp Output
B1
PNK
439
Ignition 1
B2
BLK/WHT
451
Ground
B3
PPL/WHT
455
Fuel Level PWM Output Signal From PCM
GRY
B4
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Function
Battery Feed
2/7/2011
Document ID: 359679
Page 3 of 15
Ignition 1
B5
PNK
439
B6
BLK
1250
B7
DK GRN/WHT
817
B8
BLK
1250
B9
LT BLU
14
B10
LT GRN/BLK
1360
B11
YEL
234
Ground
Ground
Turn Signal Lamp Feed - LH Front
High-Beam Headlamp Feed
Fasten Seat Belts Indicator Lamp Output
Instrument Panel Gauges Connector - Buick with UB3
12065804
Pin
Wire Color
Circuit No.
A1
DK BLU
15
A2
--
--
Not Used
A3
BLK
1250
Ground
A4
BLK
1250
Ground
A5-A6
GRY
A7-A8
--
--
Not Used
A9
LT GRN/BLK
1360
A10
--
--
Not Used
A11
LT BLU
14
B1
PNK
439
Ignition 1
B2
PPL/WHT
455
B3
PNK
439
Ignition 1
B4
WHT
121
Tachometer Signal
B5
--
--
B6
BLK/WHT
451
PCM Ground
B7
BLK/WHT
451
PCM Ground
B8
DK GRN/WHT
817
Vehicle Speed Signal - 4000 Pulses Per Mile
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Function
Not Used
2/7/2011
Document ID: 359679
Page 4 of 15
Ignition 1
B9
PNK
439
B10
TAN
31
B11
LT GRN
36
Coolant Temperature Signal
Remote Indicator Back Connector - Buick with UB3
Connector Part
Information
12191334
Pin
Wire Color
Circuit
No.
1-2
--
--
BLK
1250
YEL
234
5-7
--
--
Not Used
WHT
85
Cruise Indicator Lamp Output
GRY
803
10
DK BLU
1660
11-12
--
--
Not Used
13
DK GRN
35
Coolant Temperature Indicator Lamp Output
14
ORN
40
Battery Power
15
DK GRN
264
16
BRN
25
17
PNK
39
Fuse Output - Ignition 1
18
TAN/WHT
33
19
BRN/WHT
419
20
LT GRN/BLK
875
21
BRN
358
22
BRN/WHT
1173
Function
Not Used
Ground
Fasten Belts Indicator Lamp Output
Change Oil Indicator Lamp Output

Traction Control Indicator Lamp Driver Module
Output
Low Oil Level Indicator Lamp Output
Instrument Cluster C1 (Oldsmobile w/ UH8)

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2/7/2011
Document ID: 359679
Page 5 of 15
12045471
32 Way F Micro-Pack 100 Series (GRN)
Pin
Wire Color
Circuit No.
Function
C1
GRN LT
11
C2-C4
--
--
Not Used
C5
WHT
776
Transmission Position Switch Signal - Parity Bit
C6
GRY
773
Transmission Position Switch Signal - Bit 3
C7
YEL
772
C8
BLK/WHT
771
C9-C12
--
--
C13
PPL
209
C14
TAN/WHT
33
C15
--
--
Not Used
C16
DK BLU
15
D1-D5
--
--
Not Used
D6
LT GRN/BLK
875
D7
BRN
358
D8
--
--
Not Used
D9
PNK
439
Ignition 1
D10
--
--
Not Used
D11
BLK/WHT
99
Windshield Washer Fluid Level Sensor Signal
D12-D13
--
--
Not Used
D14
YEL/BLK
68
Low Coolant Level Indicator Lamp Output
D15
BRN/WHT
1173
D16
LT BLU
14
Not Used
Brake Fluid Level Indicator Lamp Output

Instrument Cluster Connector C2 - Oldsmobile with UH8

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2/7/2011
Document ID: 359679
Page 6 of 15
12052107
32-Way F Micro-Pack 100 Series (ORN)
Pin
Wire Color
Circuit No.
E1
GRY
E2
TAN
31
E3
PPL
30
Fuel Gauge Sensor Signal
E4
YEL
32
Fuse Output - Instrument Panel Lamps
E5
TAN
800
Serial Data Signal - UART (8192 Baud)
E6
TAN
800
Serial Data Signal - UART (8192 Baud)
E7
--
--
E8
WHT
121
E9
--
--
E10
DK GRN/WHT
817
E11
BLK
1250
Ground
E12
BLK
1250
Ground
E13
YEL
234
E14-E15
--
--
E16
LT GRN
1845
F1
--
--
F2
PPL
806
F3
ORN
40
F4
LT GRN
147
Ignition 0 (OFF/RUN)
F5
PNK
439
Ignition 1
F6
--
--
Not Used
F7
BLK/WHT
451
PCM Ground
F8
BLK/WHT
451
PCM Ground
F9
BLK
552
Sensor Return
F10-F12
--
--
F13
BRN/WHT
419
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Function
Not Used
Tachometer Signal
Not Used

Not Used
Auxiliary Chime Control Signal
Not Used
Crank
Battery Feed
Not Used
2/7/2011
Document ID: 359679
Page 7 of 15
F14
GRN DK
264
F15
--
--
Not Used
F16
PNK
439
Ignition 1
Instrument Cluster Connector - Pontiac with UB3
Connector Part
Information
12162670
Pin
Wire Color
Circuit
No.
A1
DK GRN
35
A2
TAN
31
A3
BLK
1250
A4
GRY
A5
TAN/WHT
33
A6
PNK
439
A7
LT GRN
1845
A8
BLK/WHT
451
A9
LT GRN
36
A10
DK GRN/WHT
817
A11
BLK/WHT
99
Windshield Washer Fluid level Sensor Signal
A12
BRN/WHT
1173
A13
BRN
25
A14
PPL/WHT
455
A15
PNK
439
Ignition 1
A16
DK BLU
15
A17
BLK/WHT
451
PCM Ground
B1
DK GRN/WHT
817
Vehicle Speed Signal - 4000 Pulses Per Minute
B2
PNK
439
Ignition 1
B3
BLK
1250
Function
Ground
Ignition 1
Auxiliary Chime Control Signal
PCM Ground
Coolant Temperature Sensor

Turn Signal Feed - RH Front
Ground
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2/7/2011
Document ID: 359679
Page 8 of 15
Ignition 1
B4
PNK
439
B5
BLK
1250
B6
GRY
B7
LT GRN/BLK
875
ABS Indicator - Lamp Driver Module Output
B8
YEL
234
B9
ORN
40
B10
DK GRN
264
B11
BRN/WHT
419
B12
BRN
358
B13
DK BLU
1660
B14
--
--
B15
WHT
121
B16
LT GRN
11
B17
LT BLU
14
Turn Signal Feed - LH Front
Ground
Battery

Output (with NW9)
Not Used
Tachometer Signal
Connector Part
Information
12162670
Pin
Wire Color
Circuit
No.
A1
ORN
40
A2
DK GRN
264
A3-A4
--
--
A5
DK BLU
1660
A6
BRN
358
A7
PNK
439
Ignition 1
A8-A9
--
--
Not Used
A10
TAN/WHT
33
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Function
Battery
Not Used
Output
2/7/2011
Document ID: 359679
Page 9 of 15
A11
BRN/WHT
419
A12
YEL
234
A13
DK BLU
15
A14
BLK
1250
A15
LT GRN/BLK
875
ABS Indicator - Lamp Driver Module Output
A16
BLK/WHT
99
B1
ORN
40
Battery
B2
GRY/BLK
745
Door Ajar Switch Signal - LH Front
B3
RED/BLK
744
Trunk Lid Ajar Switch Signal
B4
PNK/BLK
109
Hood Ajar Switch Signal
B5
YEL/BLK
68
B6
LT BLU/BLK
747
Door Ajar Switch Signal - LH Rear
B7
GRY
705
Reference Voltage Feed - 5 Volt Reference
B8
BLK/WHT
451
PCM Ground
B9
BLK/WHT
451
PCM Ground
B10
BLK/WHT
746
Door Ajar Switch Signal - RH Front
B11
LT GRN/BLK
748
Door Ajar Switch Signal - RH Rear
B12
YEL
32
B13
BRN
25
B14
LT GRN
11
B15
BLK
1250
B16
GRY
B17
LT BLU
14
Turn Signal Feed - LH Front
Turn Signal Feed - RH Front

Ground
Low Coolant Level Indicator Lamp Output
Ground
12065804
Pin
Wire Color
Circuit No.
A1
BRN
1141
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Function
Ignition 3
2/7/2011
Document ID: 359679
Page 10 of 15
A2
PPL/WHT
455
A3
BRN/WHT
1173
A4-A5
--
--
A6
DK GRN/WHT
1194
Low Fuel Level Signal with UV6
A7
BRN
1675
Check Gauges signal with UV6
A8
LT GRN
1845
Chime Control Signal
A9
DK GRN
35
A10
PNK
439
Ignition 1
A11
DK GRN
135
Coolant Temperature Sensor Signal
B1
TAN
31
B2
BLK
1250
B3
GRY
B4
--
--
Not Used
B5
TAN/WHT
337
B6
TAN
1278
B7
PPL/WHT
336
B8
WHT
1279
B9
WHT
121
Tachometer Signal
B10
DK GRN/WHT
817
B11
BLK
891
Boost Gauge Signal

Not Used
Ground
Compass Clock Signal

Lamp Monitor Data Request Signal
Compass Data Signal
Lamp Monitor Data Signal
Transmission Position Decoder Module -- Pontiac
12052856
Pin
Wire Color
Circuit No.
PNK
439
BLK/ WHT
451
Engine Control Module - Ground
TAN
800
Serial Data Signal
GRY
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Function
2/7/2011
Document ID: 359679
Page 11 of 15
Transmission Position Decoder Module -- Oldsmobile
12052444
8-Way F Micro Pack 100 (BLK)
Pin
Wire Color
Circuit No.
--
--
TAN
800
--
--
Not Used
GRY
--
--
Not Used
BLK/ WHT
451
--
--
PNK
439
Function
Not Used
Serial Data Signal
Engine Control Module - Ground

Not Used
Windshield Washer Solvent Level Switch

Pin
tomsn048@gmail.com
Wire Color
12162192
2-Way Metric Pack 150.2 Series (BLK)
Circuit No.
Function
2/7/2011
Document ID: 359679
Page 12 of 15
BLK
1150
BLK/ WHT
99
Ground
Electronic Compass Module
12064993
Pin
Wire Color
Circuit No.
BRN
541
--
--
PPL/WHT
336
Compass Signal Data
TAN/WHT
337
Compass Clock Signal
BRN
1141
Fuse output Ignition 3
10
BLK/WHT
251
Function
Fuse Output Battery
Not Used
Ground
Engine Oil Pressure Switch

Pin
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Wire Color
12048076
Circuit No.
Function
2/7/2011
Document ID: 359679
Page 13 of 15
TAN/BLK
31
BLK/WHT
251
C-D
--
--

Ground
Not Used
Head-up Display (HUD) Control
12064993
6-Way F Micro-Pak Series 100 (BLK)
Pin
Wire Color
Circuit No.
Function
BRN
620
BRN
1141
WHT
717
GRY
YEL
621
Head-up Display Motor Feed - Up
10
BLK/WHT
251
Ground
Head-up Display Motor Feed - Down

Illuminated Display Signal
Head-up Display (HUD) Adjuster Motor
Connector Part
Information
tomsn048@gmail.com
12059197
12-Way F Micro-Pak Series 100 (LT GRY)
2/7/2011
Document ID: 359679
Page 14 of 15
Pin
Wire Color
Circuit
No.
--
--
Not Used
YEL
32
WHT
717
DK GRN
1194
LT BLU
14
BRN
1675
Check Gauge Signal
BLK
1450
Ground
DK GRN/WHT
817
LT GRN
11
High Beam Headlamp Switch
10
DK BLU
15
Turn Signal Lamp Feed - Right Front
11
BRN
1141
12
BLK/WHT
251
Function
Illuninated Display Signal

Low Level Signal
Turn Signal Lamp Feed - Left Front
Vehicle Speed Signal - 4000 Pulses Per Mile Secondary

Ground
Hood Ajar Switch
12132192
2-Way F Metric-Pak Series 150.2 (BLK)
Pin
Wire Color
Circuit No.
PNK/BLK
109
BLK
1150
Function
Hood Ajar Switch Signal
Ground
LH Front Seat Belt Switch
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2/7/2011
Document ID: 359679
Page 15 of 15
12047662
Pin
Wire Color
Circuit No.
BLK/WHT
238
BLK
1250
Function
Seat Belt Switch Signal
Ground
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2/7/2011
Document ID: 474670
Page 1 of 2
Instrument Panel, Gauges, and Console | Repair Instructions | Document ID: 474670
Rear Compartment Switch Replacement (Buick)

Removal Procedure
1. Remove the instrument panel trim plate. Refer to Instrument Cluster Trim Panel
Replacement .
2. Remove the rear compartment release switch (2) fasteners.
3. Partially remove the switch (2).
Remove the switch (2).
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Document ID: 474670
Page 2 of 2
1. Partially install the rear compartment release switch (2).

4. Install the switch fasteners.
Tighten
5. Install the instrument panel trim plate. Refer to Instrument Cluster Trim Panel Replacement .
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2/7/2011
Document ID: 466426
Page 1 of 2
Rear Compartment Lid Valet Lock Out Switch

Replacement (Buick)
Removal Procedure
1. Open the IP compartment.

2. Carefully pry up the rear compartment release enable switch (1) or the rear compartment
release enable switch/oil reset switch (2).
Remove the switch.
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2/7/2011
Document ID: 466426
Page 2 of 2

2. Align the switch (1 or 2) to the IP compartment.
Push downward to fasten the switch.
3. Close the IP compartment.
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2/7/2011
Document ID: 299508
Page 1 of 2
Instrument Panel Multifunction Switch Replacement

(Buick)
Removal Procedure
1. Remove the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement .
2. Remove the panel lights/twilight sentinel/traction control switch (4) fasteners.

3. Pull rearward on the switch in order to remove the switch.
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Document ID: 299508
Page 2 of 2
1. Install the panel lights/twilight sentinel/traction control switch (4).

2. Install the switch fasteners.
Tighten
3. Install the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement .
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2/7/2011
Document ID: 299511
Page 1 of 2
Head Up Display Switch Replacement

Removal Procedure
2. Remove the screws (2).

3. Remove the HUD switch (1) from the IP.
tomsn048@gmail.com
2/7/2011
Document ID: 299511
1.
2.
3.
4.
Page 2 of 2

Install the HUD switch (1) to the IP.
Install the screws (2) to the IP.
Install the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement .
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2/7/2011
Document ID: 415295
Page 1 of 2
Instrument Panel Lamp Dimmer Replacement

Removal Procedure
1. Remove the instrument panel assembly. Refer to Instrument Panel Assembly Removal .
2. Remove the lamp monitor module (1) from mounting bracket.
Remove the module (1).
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2/7/2011
Document ID: 415295
1.
2.
3.
4.
Page 2 of 2
Install the module (1).

Install the module (1) to the mounting bracket.
Install the instrument panel assembly. Refer to Instrument Panel Assembly Removal .
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2/7/2011
Document ID: 299518
Page 1 of 2
Electronic Compass Module Replacement

Removal Procedure
1. Open the rear compartment lid.

2. Remove the push-in fasteners (2) retaining the compass module to the rear shelf in the rear
compartment.
3. Slide the module (1) from the mounting slot.
4. Disconnect the connector (3).
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2/7/2011
Document ID: 299518
Page 2 of 2
1. Connect the connector (3) to the module (1).

2. Install the module into the mounting slot.
3. Install the push-in fasteners (2).
Press the push-in fasteners until firmly seated.
4. Close the rear compartment lid.
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2/7/2011
Document ID: 299521
Page 1 of 2
Head Up Display Module Replacement

Removal Procedure
1. Remove the windshield defroster grille. Refer to Defroster Grille Replacement .
2. Remove the screws (1) from the HUD module (2) to IP.
3. Lift the HUD module (2) from the IP.
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2/7/2011
Document ID: 299521
1.
2.
3.
4.
Page 2 of 2

Install the lower HUD module (2) into the IP.
Install the screws (1) retaining the HUD module to the IP.
Install the windshield defroster grille. Refer to Defroster Grille Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 299523
Page 1 of 2
Instrument Panel Insulator Panel Replacement - Right

Side (Buick)
Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint (SIR) System.
Failure to follow the correct procedure could cause the following conditions:
Air bag deployment
Personal injury
Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
Refer to SIR Component Views in order to determine if you are performing service on or
near the SIR components or the SIR wiring.
If you are performing service on or near the SIR components or the SIR wiring, disable
the SIR system. Refer to Disabling the SIR System.
1. Disable the SIR. Refer to Disabling the SIR System in SIR.
2.
3.
4.
5.
6.
Remove the sound insulator screws (3) from the IP.

Remove the sound insulator wing nuts from the studs on the cowl.
Pull the sound insulator (2) down and rearward.
Remove the courtesy lamp (1).
Remove the sound insulator.
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2/7/2011
Document ID: 299523
Page 2 of 2
1. Install the courtesy lamp (1). Perform the following steps:

1.1. Position the sound insulator (2) under the dash.
1.2. Insert the cowl studs through the holes in front of the insulator.
1.3. Route the passenger inflator module pigtail around the courtesy light.
2. Install the sound insulator screws (3) to the IP.
Tighten
3. Install the wing nuts to the studs.
4. Enable the SIR. Refer to Enabling the SIR System in SIR.
tomsn048@gmail.com
2/7/2011
Document ID: 299524
Page 1 of 2
Instrument Panel Insulator Panel Replacement - Left

Side (Buick)
Removal Procedure
Important: Note the position of the fasteners prior to removal. Install the fasteners in the
same locations. Vehicles vary in the locations of the fasteners and in the quantity of fasteners
1.
2.
3.
4.
5.
6.
7.
Remove
Remove
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
the
the
sound insulator screws (3) from the IP.

wing nuts from the studs on the cowl.
data link connector (DLC).
courtesy lamp (5).
fuse panel.
turn signal flasher.
left sound insulator (4).
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2/7/2011
Document ID: 299524
Page 2 of 2
1. Install the data link connector (DLC) to the sound insulator (4).
2. Install the turn signal flasher.
3. Install the fuse panel.
Important: In order to avoid binding of the accelerator or brake pedals, ensure that the
sound insulator has proper clearance.
4. Install the courtesy lamp (5). Perform the following steps:
4.1. Position the sound insulator under the dash.
4.2. Insert the cowl studs through the holes in the front of the insulator.
5. Install the sound insulator screws to the IP.
Tighten
6. Install the wing nuts to the studs.
tomsn048@gmail.com
2/7/2011
Document ID: 299570
Page 1 of 2
Knee Bolster Replacement (Buick)

Removal Procedure
Air bag deployment
Personal injury
1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
2. Remove the right insulator panel. Refer to Instrument Panel Insulator Panel Replacement Right Side .
4. Remove the passenger side inflator module. Refer to Inflatable Restraint Instrument Panel
Module Replacement in SIR.
5.
6.
7.
8.
9.
10.
Remove the IP lower trim pad fasteners.

Partially remove the IP lower trim pad.
Disconnect the ashtray electrical connector.
Disconnect the IP storage compartment light switch electrical connector.
Disconnect the wiring harness retaining fastener.
Remove the IP lower trim pad (4).
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2/7/2011
Document ID: 299570
Page 2 of 2
1.
2.
3.
4.
5.
Partially install the IP lower trim pad (4).

Connect the wiring harness retaining fastener.
Connect the IP storage compartment light switch electrical connector.
Connect the ashtray electrical connector.
Align the IP lower trim pad.

Tighten
7. Install the passenger inflator module. Refer to Inflatable Restraint Instrument Panel Module
Replacement in SIR.
8. Install the IP cluster trim panel. Refer to Instrument Cluster Trim Panel Replacement .
9. Install the right insulator panel. Refer to Instrument Panel Insulator Panel Replacement Right Side .
10. Enable the SIR system. Refer to Enabling the SIR System in SIR.
tomsn048@gmail.com
2/7/2011
Document ID: 454790
Page 1 of 2
Instrument Cluster Trim Panel Replacement (Buick)

Removal Procedure
1. Carefully pry out the instrument panel (IP) lower trim plate (2) in order to remove.
2. Carefully pry out the air deflectors (3) in order to remove.
Important: When removing the fasteners from the air duct openings be careful not to drop
the fasteners down the openings.
3. Remove the IP trim plate fasteners (4).
4. Disengage the retaining clips at the top of the trim plate.
5. Remove the IP trim plate (5).
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2/7/2011
Document ID: 454790
Page 2 of 2
1. Align the IP trim plate (5) retaining clips to the IP.

Push inward to fasten the trim plate.
Important: When installing the fasteners to the air duct openings be careful not to drop the
fasteners down the openings.
2. Install the IP trim plate fasteners (4).
Tighten
3. Snap in the air deflectors (3).
4. Install the IP lower trim plate (2).
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2/7/2011
Document ID: 299580
Page 1 of 3
Instrument Panel Storage Compartment Replacement

(Buick)
Removal Procedure
1. Open the instrument panel (IP) compartment.
2. Pull down the IP compartment stops. Allow the compartment to travel past the stops.
3. Remove the rear compartment release enable switch/oil reset switch, if equipped. Refer to
Rear Compartment Lid Valet Lock Out Switch Replacement .
4. Disengage the electrical connector retainer fastening the electrical connector to the rear of
the IP compartment.
5. Remove the IP compartment light (1) from the IP compartment assembly.

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2/7/2011
Document ID: 299580
Page 2 of 3
7. Remove the fasteners (1) securing the IP compartment to the IP.

Remove the IP storage compartment hinge trim (2).
8. Open the IP compartment in order to remove the IP compartment.
1. Install the IP compartment to the IP.

Place the IP compartment in the closed position.
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2/7/2011
Document ID: 299580
Page 3 of 3
2. Install the hinge trim (2) to the hinge.

3. Install the fasteners (1) in order to secure the IP compartment to the IP.
Tighten
4. Open the IP compartment.
5. Pull down the IP compartment stops. Allow the compartment to travel past the stops.
6. Install the IP compartment light (1) to the IP compartment.

7. Connect the electrical connector retainer to the rear of the IP compartment.
8. Install the rear compartment release enable switch/oil reset switch, if equipped. Refer to
Rear Compartment Lid Valet Lock Out Switch Replacement .
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2/7/2011
Document ID: 299581
Page 1 of 4
Instrument Panel Compartment Door Lock Cylinder

Replacement (Buick)
Removal Procedure
1. Remove the IP compartment. Refer to Instrument Panel Storage Compartment Replacement .
2. Remove the fasteners (1) retaining the IP compartment to the door.

3. Remove the door from the IP compartment.
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2/7/2011
Document ID: 299581
Page 2 of 4
4. Remove the latch assembly fasteners (1, 2).

5. Remove the latch assembly.
6. Remove the retainer clip (1) from the lock assembly.

7. Remove the lock assembly.
8. Push a paper clip through the hole in the back of the latch in order to hold down the silver
tumbler on the lock cylinder.
9. While holding down the tumbler, insert the key.
10. Rotate the cylinder turn counter-clockwise.
11. Remove the lock cylinder.
1. While pushing down the silver tumbler on the lock cylinder, insert the key into the lock
cylinder keyhole.
2. Install the lock cylinder to the lock assembly.
3. Turn the key turn clockwise. Remove the key.
4. Install the lock assembly to the door.
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2/7/2011
Document ID: 299581
Page 3 of 4
5. Install the lock assembly retainer (1).
6. Install the latch assembly.

7. Install the latch assembly fasteners (1, 2).
8. Install the door to the IP compartment.
tomsn048@gmail.com
2/7/2011
Document ID: 299581
Page 4 of 4
9. Install the door assembly fasteners (1).

10. Install the IP compartment to the IP. Refer to Instrument Panel Storage Compartment
Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 412712
Page 1 of 1
Defroster Grille Replacement (Buick)

The defroster grille is part of the IP upper trim panel to service the defroster grille Refer to
Instrument Panel Upper Trim Pad Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 323358
Page 1 of 2
Sunload and Twilight Sentinel Sensor Replacement

Removal Procedure
1. Remove the IP upper trim panel. Refer to Instrument Panel Upper Trim Pad Replacement or
Defroster Grille Replacement .
2. Disconnect the sunload (2) and the twilight sentinel (3) sensors from the IP upper trim panel
by turning a quarter turn.
Remove the sensors from the trim panel.
3. Remove the sensors.
tomsn048@gmail.com
2/7/2011
Document ID: 323358
1.
2.
3.
4.
Page 2 of 2
Install the sensors.

Install the sensors (2, 3) to the upper trim panel.
Turn the sensors a quarter turn to secure the sensors.
Install the upper trim panel. Refer to Instrument Panel Upper Trim Pad Replacement or
Defroster Grille Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 323362
Page 1 of 2
Instrument Panel Upper Trim Pad Replacement (Buick)

Removal Procedure
1. Perform the following steps in order to remove the reveal covers (1):
1.1. Pry the covers up.
1.2. Carefully pull forward on the covers.
2. Remove the fasteners (2):
3. Carefully pull up the upper trim panel (5).
4. Remove the sunload and the twilight sentinel sensors. Refer to Sunload and Twilight Sentinel
Sensor Replacement .
5. Remove the upper trim panel.
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2/7/2011
Document ID: 323362
Page 2 of 2
1. Partially install the IP upper trim panel (5).

2. Insert the sensors. Refer to Sunload and Twilight Sentinel Sensor Replacement .
3. Install the upper trim panel.
Tighten
5. Install the reveal covers (1).
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2/7/2011
Document ID: 323366
Page 1 of 4
Instrument Panel Assembly Removal (Buick)

Removal Procedure
After a non-deployment accident, visually inspect the IP assembly for damage or deformation. Any
visible damage indicate structural damage and therefore mandates IP assembly replacement.
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
Air bag deployment
Personal injury
2.
3.
4.
5.
Disable the SIR system. Refer to Disabling the SIR System in SIR.
Remove the upper trim panel. Refer to Instrument Panel Upper Trim Pad Replacement .
Remove the information center telltale. Refer to Driver Information Center Replacement .
Remove the IP trim plates. Refer to Instrument Cluster Trim Panel Replacement .
Air bag deployment
Personal injury
6. Remove the passenger inflator module. Refer to Inflatable Restraint Instrument Panel Module
Replacement in SIR.
7. Remove the rear compartment lid release enable/oil reset switch. Refer to Rear Compartment
Lid Valet Lock Out Switch Replacement .
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2/7/2011
Document ID: 323366
Page 2 of 4
8. Remove the ashtray. Refer to Ashtray Replacement .

9. Remove the IP lower trim pad. Refer to Knee Bolster Replacement .
Important: Remove the steering column lower mounting bolts prior to removing the upper
mounting bolts or damage to the lower steering column bearing may occur. Place a
protective cloth on the steering column in order to protect the column from scratches.
10. Lower the steering column. Refer to Steering Column Replacement in Steering Wheel and
column tilt.
11. Remove the IP assembly upper fasteners (1).

12. Remove the IP lower fasteners (2).
13. Remove the fasteners (1) from the IP center support.

14. Pull the IP assembly rearward slightly.
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2/7/2011
Document ID: 323366
15.
16.
17.
18.
Page 3 of 4
Disconnect the electrical connectors, including the antenna coax cable.

Disconnect the aspirator hose.
Remove the IP assembly.
Transfer all necessary components.
1. Partially install the IP assembly.
2. Connect the electrical connectors, including the antenna coax cable.
3. Connect the aspirator hose.
4. Install the IP assembly top fasteners (1) to the outer brackets.
Tighten
5. Install the fasteners (2) to the left and right lower front of the IP.
Tighten
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2/7/2011
Document ID: 323366
Page 4 of 4
6. Install the fasteners (1) to the IP center support.

Tighten
7. Raise the steering column. Refer to Steering Column Replacement in Steering Wheel and
column tilt.
8. Install the IP lower trim pad. Refer to Knee Bolster Replacement .
9. Install the ashtray. Refer to Ashtray Replacement .
10. Install the rear compartment lid release enable/oil reset switch. Refer to Rear Compartment
Lid Valet Lock Out Switch Replacement .
11. Install the passenger inflator module. Refer to Inflatable Restraint Instrument Panel Module
Replacement in SIR.
12. Install the instrument panel trim plates. Refer to Instrument Cluster Trim Panel
Replacement .
13. Install the information center telltale . Refer to Driver Information Center Replacement .
14. Install the upper trim panel . Refer to Instrument Panel Upper Trim Pad Replacement .
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and
Connection in Engine Electrical.
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2/7/2011
Document ID: 456281
Page 1 of 2
Steering Column Bracket Replacement

Removal Procedure
Air bag deployment
Personal injury
2. Remove the IP assembly. Refer to Instrument Panel Assembly Removal .
3. Remove the fasteners attaching the steering column support bracket brace to the inner
panel.
4. Remove the fasteners retaining the steering column support brackets to the steering column
support bracket brace.
5. Remove the fasteners attaching the steering column support bracket brace (1) to the
steering column support bracket.
6. Remove the steering column support bracket brace (1) from the vehicle.
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2/7/2011
Document ID: 456281
Page 2 of 2
1. Install the steering column support bracket brace (1) to the vehicle.
2. Install the fasteners attaching the steering column support bracket brace to the steering
column support bracket.
Tighten
3. Install the fasteners attaching the steering column support bracket brace to the inner panel.
Tighten
4. Install the fasteners retaining the steering column support brackets to the steering column
support bracket brace.
Tighten
5. Install the IP assembly. Refer to Instrument Panel Assembly Removal .
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2/7/2011
Document ID: 323374
Page 1 of 3
Instrument Cluster Replacement (Buick)

Removal Procedure
Air bag deployment
Personal injury
2. Remove the IP trim plate. Refer to Instrument Cluster Trim Panel Replacement .
3. Remove the PRNDL cable (1).

4. Remove the panel lights twilight sentinel/traction control switch. Refer to Instrument Panel
Multifunction Switch Assembly Replacement .
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2/7/2011
Document ID: 323374
Page 2 of 3
5. Remove the cluster fasteners (1).

6. Remove the instrument cluster (2).
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2/7/2011
Document ID: 323374
Page 3 of 3

1. Install the instrument cluster (2) and the fasteners (1).
Tighten
2. Install the panel lights twilight sentinel/traction control switch. Refer to Instrument Panel
Multifunction Switch Assembly Replacement .
3. Install the PRNDL cable (1).

4. Install the IP trim plate. Refer to Instrument Cluster Trim Panel Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 323378
Page 1 of 1
Instrument Cluster Lens Replacement

Removal Procedure
1.
2.
3.
4.
Remove the IP cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement .
Remove the instrument cluster lens fasteners to the instrument cluster , if necessary.
Release the instrument cluster lens retainers, if necessary.
Remove the instrument cluster lens.
Ensure the instrument cluster lens surface is completely clean before assembly.
1. Install the instrument cluster lens to the instrument cluster.
2. Carefully push inward on the outside of the lens in order to fasten the lens retainers, if
necessary.
3. Install the instrument cluster lens fasteners to the instrument cluster, if necessary.
Tighten
4. Install the IP cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement .
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2/7/2011
Document ID: 479129
Page 1 of 2
Ashtray Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
Open the ashtray.

Remove the fasteners (1) retaining the ashtray.
Remove the ashtray partway.
Remove the ashtray.
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2/7/2011
Document ID: 479129
Page 2 of 2

2. Align the ashtray with the lower trim pad.
3. Install the ashtray fasteners (1).
Tighten
4. Close the ashtray.
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2/7/2011
Document ID: 415601
Page 1 of 2
Cigar Lighter Housing Replacement (Buick/Oldsmobile)

Removal Procedure
1.
2.
3.
4.
Pull rearward the ashtray.

Disconnect electrical connector (2).
Remove the cigar lighter socket retainer.
Remove the cigar lighter socket.
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2/7/2011
Document ID: 415601
1.
2.
3.
4.
Page 2 of 2
Install the cigar lighter socket.

Install the cigar lighter socket retainer.
Push forward the ashtray.
tomsn048@gmail.com
2/7/2011
Document ID: 457298
Page 1 of 2
Front Floor Console Trim Plate Replacement

Removal Procedure
1. Open the armrest bin lid.

2. Lift on the tab to disengage the armrest bin lower trim plate.
Remove the armrest bin lower trim plate (4).
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2/7/2011
Document ID: 457298
Page 2 of 2
1. Align the forward tabs on the trim plate (4) with the console duct.
2. Rotate the trim plate down.
Press the trim plate (4) into place.
3. Close the armrest bin lid.
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2/7/2011
Document ID: 323388
Page 1 of 2
Fuse Block Access Cover Replacement

Several fuses are also located in the relay center.
Removal Procedure
1. Depress the release tab.

2. Pull down on the cover (3).
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2/7/2011
Document ID: 323388
Page 2 of 2
1. Insert tabs on the fuse block cover (3) into the sound insulator.
2. Push upward to fasten the fuse block cover.
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2/7/2011
Document ID: 323389
Page 1 of 2
Driver Information Center Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
Remove the upper trim plate. Refer to Instrument Panel Upper Trim Pad Replacement .
Remove the information center fasteners (2).
Remove the information center (4).
Disconnect the information center connector (3).
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2/7/2011
Document ID: 323389
Page 2 of 2
1. Connect the connector (3).

2. Install the information center (4).
Tighten
4. Install the upper trim plate. Refer to Instrument Panel Upper Trim Pad Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 323391
Page 1 of 1
Instrument Cluster Head Up Display Window Cleaning

Notice: Do not spray the window cleaner directly on the Head-Up Display (HUD) window,
because this may cause damage to the HUD internal components.
1. Spray glass cleaner on a soft, clean cloth.
2. Gently wipe the HUD window using the cloth.
3. Dry the window.
tomsn048@gmail.com
2/7/2011
Document ID: 299689
Page 1 of 1
Interior Trim | Specifications | Document ID: 299689

Specification
Application
Metric
English
Load Bar Bolt
42 Nm
31 lb ft
Rear Seat Lap Belt Nut
35 Nm
25 lb ft
Seat Adjuster to Floor Pan Nut
34 Nm
25 lb ft
Seat Adjuster to Seat Cushion Frame Bolts
24 Nm
17 lb ft
2/7/2011
Document ID: 299691
Page 1 of 2
Interior Trim | Repair Instructions | Document ID: 299691
Front Floor Mat/Carpet Replacement

Removal Procedure
Caution: In order to avoid personal injury or vehicle damage when you repair or replace the
carpet, use the same thickness and material size as the original installation. Always return the
carpet to the original location.
1. Remove the front seats. Refer to Seat Replacement in Seats.

2. Remove the inboard seat belt buckles (as needed). Refer to Seat Belt Buckle Replacement Left Front or Seat Belt Buckle Replacement - Right Front in Seat Belts.
3. Remove the seat belt retractor covers. Refer to Seat Belt Retractor Replacement - Left Front
or Seat Belt Retractor Replacement - Right Front in Seat Belts.
4. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
5. Remove the center console (as applicable). Refer to Console Replacement in Instrument
6. Remove the carpet retainers. Refer to Carpet Retainer Replacement .
7. Remove the following components from under the instrument panel:
The closeout / insulator panel-right. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges and Console.
The closeout / insulator panel-left. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
8. Ensure care is taken when carpeting is removed that seat wiring is pushed through the
opening in the carpet.
9. Remove the floor carpet (2).
2/7/2011
Document ID: 299691
Page 2 of 2
Caution: In order to avoid personal injury or vehicle damage when you repair or replace the
carpet, use the same thickness and material size as the original installation. Always return the
carpet to the original location.
1. Position the floor carpet (2).

2. Pull the seat wiring through the opening in the carpet.
3. Install the following components under the instrument panel:
The closeout / insulator panel-left. Refer to Instrument Panel Insulator Panel Replacement
- Left Side in Instrument Panel, Gauges and Console.
4.
5.
6.
7.
8.
9.
The closeout / insulator panel-right. Refer to Instrument Panel Insulator Panel

Replacement - Right Side in Instrument Panel, Gauges and Console.
Install the carpet retainers. Refer to Carpet Retainer Replacement .
Install the center console (as applicable). Refer to Console Replacement in Instrument Panel,
Gauges and Console.
Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
Install the seat belt retractor covers. Refer to Seat Belt Retractor Replacement - Left Front or
Seat Belt Retractor Replacement - Right Front in Restraints.
Install the inboard seat belt buckles (as applicable). Refer to Seat Belt Buckle Replacement Left Front or Seat Belt Buckle Replacement - Right Front in Restraints.
Install the front seats. Refer to Seat Replacement in Seats.
2/7/2011
Document ID: 482972
Page 1 of 2
Carpet Retainer Replacement

Removal Procedure
1. Pull downward the front and rear door weatherstrips (1) in order to remove the center pillar
garnish moldings.
2. Pull outward the center pillar garnish molding (2) in order to release the retainers securing
the center trim to the body.
4. Remove the rear finish shrouds.
5. Pull upward the carpet retainer (3) in order to release the retainer from the floor support
clips.
6. Carefully slide the shoulder belt through the opening in the carpet retainer.
7. Remover the carpet retainer (3).
2/7/2011
Document ID: 482972
Page 2 of 2
1. Slide the shoulder belt through the opening in the carpet retainer.
2. Align the carpet retainer (3) to the floor support clips.
3. Apply downward pressure to the carpet retainer in order to secure the retainer to the support
clips.
4. Install the rear finish shrouds.
5. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Seats.
6. If the retainer clips on the center pillar garnish molding are damaged or broken, replace, do
not reuse.
7. Install the center pillar garnish molding (2).
8. Push inward at the top and bottom in order to secure.
9. Install the front and rear door weatherstrips (1) while applying pressure to the strips in order
to secure.
2/7/2011
Document ID: 299692
Page 1 of 6
Headlining Trim Panel Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
Remove
Remove
Remove
Remove
the
the
the
the
front door weather-strips.

rear door weather-strips (3).
center pillar trim (4).
upper rear quarter panel trim (1).
5. Remove the windshield

garnish
molding
2011
General
Motors (1).
Corporation. All rights reserved.
2/7/2011
Document ID: 299692
Page 2 of 6
6. Remove the sunroof opening closeout lace, if equipped.
7. Remove the sunshades (1). Refer to Sunshade Replacement .

8. Remove the assist handles, if equipped. Refer to Assist Handle Replacement .
9. Remove the coat hooks, if equipped.

10. Remove the interior lamps (1).
11. Remove the fiber optic cover, if equipped.
2/7/2011
Document ID: 299692
Page 3 of 6
Notice: Use care when removing and installing the headliner. If reusing the headliner lay the
headliner down flat on a clean surface. Excessive bending will damage the headliner.
Important: Five to six patches of hook and loop material secure the headliner to the roof. In
order to avoid tearing the fiberglass substrate, carefully separate them. Recline the seat back
and position the seat as far rearward as possible.
12. Remove the headliner (1) through the right front door.
2/7/2011
Document ID: 299692
Page 4 of 6
1. Install the headliner (1) through the right front door, with the aid from an assistant.
2. Install the coat hooks (1), if equipped.

3. Install the assist handles, if equipped. Refer to Assist Handle Replacement .
2/7/2011
Document ID: 299692
Page 5 of 6
4. Install the sunshades (1). Refer to Sunshade Replacement .

5. Install the interior lamps.
6. Install the fiber optic cover, if equipped.
7. Install the windshield garnish molding (1).

8. Install the sunroof opening closeout lace, if equipped.
2/7/2011
Document ID: 299692
9.
10.
11.
12.
Install
Install
Install
Install
the
the
the
the
Page 6 of 6
upper rear quarter panel trim (1).

center pillar molding (3).
rear door weather-strips (2).
front door weather-strips.
2/7/2011
Document ID: 299695
Page 1 of 2
Assist Handle Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the push-pin (3) from the rail mounted assist handle.
Remove the fasteners from under the assist handle (1).
Carefully lower the assist handle from the headliner.
Disconnect the wiring harness connector, if equipped.
Remove the assist handle.
2/7/2011
Document ID: 299695
Page 2 of 2
1. Connect the wiring harness connector, if equipped.

2. Align the following components:
The retainer behind the headliner
The headliner opening
The assist handle
3. Install the push-pins.
4. Press the push-pin (3) into place in order to secure the assist handle to the roof.
2/7/2011
Document ID: 299696
Page 1 of 2
Sunshade Replacement
Removal Procedure
1.
2.
3.
4.
5.
Remove the push-pin from the center support (1).

Remove the fasteners (2) from the socket side of the sunshade.
Detach the sunshade from the center support (1).
Partially pull downward on the sunshade in order to remove the sunshade from the headliner.
Partially lower the headliner in order to disconnect the wiring harness connector (if the
vehicle is equipped with a lighted vanity mirror). Refer to Headlining Trim Panel
Replacement .
1. Install the headliner, (if the vehicle was equipped with a lighted vanity mirror). Refer to
Headlining Trim Panel Replacement .
2. Carefully guide the electrical harness through the headliner opening, if equipped with a
lighted vanity mirror.
2/7/2011
Document ID: 299696
3.
4.
5.
6.
7.
8.
Page 2 of 2
Connect the wiring harness connector.

Install the sunshade through the openings in the headliner.
Snap the retainer behind the headliner into place.
Install the fasteners (2) in order to secure the sunshade to the roof.
Install the push-pins to the center support (1).
Check the operation of the lighted vanity mirror (if equipped).
2/7/2011
Document ID: 299697
Page 1 of 2
Vanity Mirror Replacement

Removal Procedure
1. Open the vanity cover.

2. Use a thin-bladed tool in order to disengage the 2 front snap legs at the lower edge of the
sunshade.
3. Pull the vanity out and downward in order to access the electrical connections.
Important: Note the wire routing for installation.
4. Disconnect the wire connectors from the vanity, if equipped.
5. Remove the vanity mirror.
2/7/2011
Document ID: 299697
1.
2.
3.
4.
Page 2 of 2
Connect the wire connectors, if equipped.

Insert the top end of the vanity into the sunshade.
Firmly apply pressure to engage the snap legs.
Close the vanity mirror cover.
2/7/2011
Document ID: 299698
Page 1 of 2
Windshield Pillar Garnish Molding Replacement

Removal Procedure
1. Carefully disengage the retainers on the back side of the molding (1).
2. Pull outward on the garnish molding.
3. Remove the windshield pillar garnish molding (1).
2/7/2011
Document ID: 299698
Page 2 of 2
1. Connect the new retainers (2) to the windshield pillar garnish molding (1) if they are broken
or damaged.
2. Align the retainers (2) to the holes in the windshield pillar.
3. Press the windshield pillar garnish molding (1) in order to secure.
2/7/2011
Document ID: 299699
Page 1 of 2
Center Pillar Garnish Molding Replacement

Removal Procedure
1. Pull the door weatherstrip moldings downward to the top of the carpet retainer.
2. Pull the trim panel (2) straight away from the vehicle at the following positions:
The middle
The bottom
3. Pull the trim panel down at the top.
4. Slide the shoulder belt through the opening at the top of the trim panel.
5. Remove the trim panel from the vehicle at the following attached locations:
The top
The middle
The bottom
2/7/2011
Document ID: 299699
Page 2 of 2
1. Slide the shoulder belt through the opening at the top of the trim panel (2).
2. Slide the trim panel into the retainers at the top of the vehicle.
3. Push the trim panel into place at the following locations:
The top
The middle
The bottom
4. Install the door weatherstrip moldings.
5. Press the weatherstrips firmly into place.
2/7/2011
Document ID: 299702
Page 1 of 2
Rear Quarter Trim Panel Replacement

Removal Procedure
Tools Required
J 38778 Door Trim Pad Clip Remover
1.
2.
3.
4.
5.
Grasp the roof inner side rear finish molding next to the upper quarter trim panel.
Pull the molding toward the front of the vehicle in order to loosen the molding from the body.
Disengage the retainers on the backside of the upper quarter trim panel (1).
Pull the panel toward the inside of the vehicle.
Remove the upper quarter trim panel (1).
2/7/2011
Document ID: 299702
Page 2 of 2
1. Install new retainers to the upper quarter trim panel (1) if the retainers are broken or
damaged.
2. Align the upper trim panel retainers to the holes in the body panel.
3. Press the trim panel (1) into place.
4. Align the inner side rear finish molding to the body.
5. Press the molding into place in order to secure.
2/7/2011
Document ID: 416245
Page 1 of 2
Rear Window Shelf Trim Panel Replacement

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
Remove the rear quarter trim panels. Refer to Rear Quarter Trim Panel Replacement .
Remove the push-in retainers at the front of the rear window trim panel.
Lift upward the rear window trim panel.
Carefully guide the rear shoulder belts from the opening in the rear window trim panel.
Pull upward the rear window trim panel.
Remove the rear window trim panel.
2/7/2011
Document ID: 416245
1.
2.
3.
4.
5.
Page 2 of 2
Install the rear window trim panel.

Carefully guide the rear shoulder belts through the opening in the rear window trim panel.
Install the push-in retainers at the front of the rear window trim panel.
Install the quarter trim panels. Refer to Rear Quarter Trim Panel Replacement .
Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
2/7/2011
Document ID: 378772
Page 1 of 2
Keyless Entry | Schematic and Routing Diagrams | Document ID: 378772
Keyless Entry Schematics

Cell 132: RFA Power, Ground and DLC
Cell 132: RFA Inputs and Outputs
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2/7/2011
Document ID: 378772
Page 2 of 2
tomsn048@gmail.com
2/7/2011
Document ID: 379561
Page 1 of 1
Keyless Entry | Component Locator | Document ID: 379561
Keyless Entry Component Views

(1) RH IP Fuse Block

(2) Remote Function Actuator (RFA) Module
(3) S261
(4) S266
(5) S278
(6) S272
tomsn048@gmail.com
2/7/2011
Document ID: 401327
Page 1 of 2
Keyless Entry | Component Locator | Document ID: 401327
Keyless Entry Connector End Views

Remote Function Actuator
Connector Part
Information
12110115
32-Way F Micro-Pack 100 Series (BLU)
Pin
Wire Color
Circuit
No.
E1
LT BLU
1344
E2
BLK
28
E3
DK BLU/WHT
653
Key In Ignition Chime Output
E4
LT BLU
195
Door Lock Request Output
E5
ORN/BLK
781
Door Unlock Request Output/Door Unlock Input

From Switch
E6
LT GRN
1391
LH Front Door Lock Isolation Relay Control
E7
PPL
1807
Serial Data Signal - Class 2 (10400 BAUD)
E8
--
--
Not Used
E9
LT GRN
80
Key In Ignition Switch Signal
E10
DK BLU/WHT
727
Door Open Signal - LH Front
E11
LT GRN
262
Door Lock Cylinder Switch Signal - Key Unlock Input
E12
DK BLU
49
E13
RED/BLK
780
Power Door Lock Input Signal From Switch
E14
LT GRN
275
Park/Neutral Position Switch Output - Park
E15
PNK
39
E16
ORN
1540
Function
Rear Compartment Release Output - Coil
Horn Relay Output - Coil
Door Open Input Signal

Fuse Output - Battery
F1
LT GRN/BLK
394
Interior Light Control
F2
PPL
1985
Memory Seat/Mirror Module Signal - Personalization

Bus
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2/7/2011
Document ID: 401327
Page 2 of 2
F3
DK GRN
1655
Perimeter Lighting Relay Control
F4
BLK/WHT
624
Headlamp Flash Control
F5
DK GRN
264
F6
BLK
707
Delayed Accessory Bus Relay Feed - Accessory

Relay
F7-F9
--
--
F10
LT BLU
263
F11-F12
--
--
F13
BLK/WHT
1455
F14
--
--
F15
YEL
143
F16
BLK
1050
Not Used
Not Used
Keyless Entry Program Enable Signal
Not Used
Fuse Output - Accessory
Gound
tomsn048@gmail.com
2/7/2011
Document ID: 299655
Page 1 of 2
Keyless Entry | Repair Instructions | Document ID: 299655
Remote Control Door Lock Receiver Replacement

Removal Procedure
1. Remove the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel Gauges and Console.
2. Disconnect the lower electrical connector.

2.1. Press down on the center tab of the multi-use bracket (1).
2.2. Slide the module (3) downward until the mounting rails are disengaged.
3. Disconnect the upper electrical connector.
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2/7/2011
Document ID: 299655
Page 2 of 2
Important: Carefully follow the installation procedure when replacing the RFA module in
order to avoid malfunctions or inoperative options. If the RPO options are improperly set, the
RFA system may become inoperative.
1. Connect the upper electrical connector.
1.1. Align the mounting rails on the module (3) with the mounting rails on the multi-use
bracket (1).
2.
3.
4.
5.
1.2. Slide the module (3) upward into place until the mounting rails align and the locking
tab engages.
Connect the lower electrical connector.
Install the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel Gauges and Console.
Program the RFA module. Refer to Remote Control Door Lock Reprogramming .
Program the transmitters. Refer to Transmitter Programming .
tomsn048@gmail.com
2/7/2011
Document ID: 379583
Page 1 of 5
Remote Control Door Lock Reprogramming

Important: Before entering the programming mode, verify possession of all the transmitters you
will be using on the vehicle. Once you program the transmitter, the memory erases. The other
transmitters will not be functional until you program the transmitters again. You may program up
to 4 transmitters.
Accessing RFA Programming

1.
2.
3.
4.
Enter
Enter
Enter
Enter
Diagnostics.
Body.
all vehicle information that is requested, such as, make/model/year.
Remote Function Actuator.
Scan Tool Displays

Use the scan tool to set the programming options for the vehicle. The following information
explains the different option screens on the scan tool.
Module Information
RFA module software ID
Inputs
Ignition 1
Accessory 1
Door lock switch
Door key cylinder lock switch
Passenger door ajar switch
Perimeter lights
Theft tamper switch
Park switch
Outputs
Trunk release
Exterior lamps
Horn
Door lock
Door unlock
Driver unlock
Security lamp
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2/7/2011
Document ID: 379583
Page 2 of 5
Courtesy lamp
Awarn - Alarm Warning
Perimeter lights
RAP
Special Functions
Output Control
Alarm warning
Horn
Courtesy lamps
Security telltale
PBUS - Personalization bus
Trunk release
Driver door relay
Retained accessory power
Perimeter lighting
Door lock
Door unlock
Set Options
Choose Activate or Deactivate to select each option. Use the RPO list and the vehicle option tag to
verify the correct options to turn on.
Option # 0
Activation verification
Automatic door locks
Theft
Delayed locking
Perimeter lights
Panic button
Central locking
Option # 1
Options
Turn off RF for export
Vehicle type (Inactive =Olds/Buick)
Personalization message
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2/7/2011
Document ID: 379583
Page 3 of 5
The following lists are for setting specific modifications. Each transmitter can be programmed for a
specific driver's preference.
Fob #1 Option # 1
Perimeter lighting
Delayed locking
Fob #1 Option # 2
Important: Pontiac Bonnevilles ADL feature is different than the Buick and Oldsmobile. The
Bonneville will lock the doors when the shifter is moved out of park and only unlock the
doors when the ignition key is moved to the off position.
Automatic door locks Mode 0 - No automatic door lock or unlock.
Automatic door locks Mode 1 - Automatically locks all doors when the transmission is shifted
out of park. But doors do not unlock automatically.
out of park and automatically unlocks the driver's door when shifted into park or for the
Bonneville by moving the ignition key to the off position.
out of park and automatically unlocks all doors when shifted into park or for the Bonneville
by moving the ignition key to the off position.
Fob #1 Option # 3
Activation verification Mode 0 Remote Activation Verification (RAV) Customization .
Option # 0
Activation verification
Automatic door locks
Theft
Delayed locking
Perimeter lights
Panic button
Central locking
Option # 1
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2/7/2011
Document ID: 379583
Page 4 of 5
Options
Turn off RF for export
Vehicle type (Inactive =Olds/Buick)
Personalization message
Fob # 2 Option # 1
Perimeter lighting
Delayed locking
Fob # 2 Option # 2
Automatic door locks Mode 0
Fob # 2 Option # 3
Activation verification Mode 0
Feature
Buick
Pontiac
Oldsmobile
This list details the possible option codes for the vehicles. This information is to be used to
program a RFA module that has been replaced. If the RFA module is not programmed
properly, certain options or functions will not operate properly.
Delayed Illumination
STD
STD
STD
Theatre Dimming
STD
STD
STD
Load Protection
STD
STD
STD
Lock-Out Prevention
STD
STD
STD
Delayed Locking
STD
STD
STD
Programmable Auto Door Locks
AU4
AU4
AU4
Keyless Entry
AU0
AU0
T2T
Panic
AU0
AU0
AU0
Retained Accessory Power
N/A
C97
T2T
Personalization
AU0
AU0
T2T
Transmitter Chirp
AU0
AU0
T2T
Perimeter Lighting
AU0
AU0
T2T
Illuminated Entry
N/A
C97
T2T
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2/7/2011
Document ID: 379583
Page 5 of 5
Theft Deterrent System
UA6
UA6
N/A
Central Unlocking
UA6
UA6
N/A
tomsn048@gmail.com
2/7/2011
Document ID: 379586
Page 1 of 1
Remote Activation Verification (RAV) Customization

The Remote Activation Verification (RAV) provides feedback to the driver that the vehicle has
received as the command from the transmitter.
The driver may select the following modes:
Mode
Unlock Vehicle
Lock Vehicle
Turn the feature off
Single flash exterior lamps
No feedback
No feedback
No feedback
Single flash exterior lamps and chirp horn
Single flash exterior lamps and chirp horn
Customize the activation feature to each transmitter using the following procedure:
1. Hold the power door lock switch down.
The doors lock.
2. Press the TRUNK button on the transmitter.
The RAV mode stays in the current mode. The horn chirps.
3. Press the TRUNK button on the transmitter.
The RAV mode changes to the next mode. The horn chirps.
4. Release the power door lock switch.
The customization mode terminates.
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Document ID: 399386
Page 1 of 2
Transmitter Battery Replacement

Removal Procedure
1. Replace the batteries when the range of the transmitter decreases to less than 7 m (23 ft).
2. Insert a small coin between the two halves of the transmitter case at the slot provided near
the key ring hole.
3. Twist the coin in order to open the case.
4. Open the transmitter case.
5. Remove the battery (2).

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Document ID: 399386
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1. Install the battery (2) with the positive (+) side down.
Use one 3 V CR2032 battery (or the equivalent).
2. Close the transmitter case (6, 4).
3. Ensure that the seal is in position. Align the two halves of the case and snap the two halves
together.
4. Reprogram the transmitter. Refer to Transmitter Programming .
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Document ID: 299657
Page 1 of 1
Transmitter Synchronization
The keyless entry transmitters may become out of synchronization with the remote function
actuator ( RFA) module under the following conditions:
When changing the transmitter battery.
Excessively pressing the transmitter buttons while out of the vehicles range.
When a transmitter becomes out of synchronization, only the panic feature will operate from the
transmitter.
To resynchronize the transmitter, perform the following steps:
1. Hold the transmitter within the range of the vehicle.
2. Press and hold the transmitter LOCK (4) and UNLOCK (1) buttons simultaneously for
8 seconds.
When the transmitter is synchronized with the vehicle, the door locks will cycle. The horn will
chirp and the exterior lights will flash if programed to do these functions.
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Document ID: 299658
Page 1 of 1
Transmitter Programming
Important: Before entering the programming mode, verify possession of all the transmitters you
will be using on the vehicle. Once you program the transmitter, the memory erases. The other
transmitters will not be functional until you program the transmitters again. You may program up
to 4 transmitters.
Perform the following procedure when adding new transmitters or replacing failed transmitters:
1. Turn the ignition switch OFF.
2. Use a fused jumper wire in order to jumper the DLC terminal 8 (BLK/WHT) to terminal 4
(BLK).
3. Close all of the doors.
4. Turn the ignition switch ON.
The doors will cycle to lock.
5. Press and hold the LOCK button and the UNLOCK button on one transmitter.
After a 30 second delay the doors will lock and unlock.
Important: Do not turn the ignition OFF or the first transmitter will become inoperative.
6. In order to program extra transmitters, repeat step 5.
7. Disconnect the fused jumper wire from the DLC.
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Document ID: 297894
Page 1 of 1
Lighting Systems | Specifications | Document ID: 297894

Specification
Application
Metric
English
Backup Lamp to Rear Compartment Lid
9 Nm
80 lb in
Daytime Running Lamp Resistor to Body
7 Nm
62 lb in
Headlamp Bracket to Body
9 Nm
80 lb in
Taillamp to Quarter
9 Nm
80 lb in
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Document ID: 297895
Page 1 of 1
Lighting Systems | Specifications | Document ID: 297895
Bulb Usage
Indicator
Bulbs to Check
Important: When replacing a bulb, ensure that you replace the bulb with the same type. If
you use the incorrect bulb, the driver information center (DIC) will continue to display a bulb
outage.
If the driver information center (DIC) displays bulb indicator outages, use the following chart
before proceeding with the diagnosis in order to determine if a bulb is burnt out. Verify the
proper bulb type.
The high beam indicator lights.
The 2 high beam bulbs
The low beam indicator lights.
The 2 low beam bulbs

The LH park/turn bulb
The LH side marker bulb
The park lamp lights.
The RH park/turn bulb

The RH side marker bulb
The LH front turn signal bulb.
The RH front turn signal bulb.
The turn lamp lights.
The LH rear turn signal bulb.

The RH rear turn signal bulb.
The 2 left tail bulbs
The 2 right tail bulbs
The taillamp indicator lights.
The 2 licence bulbs

The 4 tail/turn/stop bulbs
The LH rear side marker bulb
The RH rear side marker bulb
The backup indicator lights.

The brake lamp indicator comes on
The taillamp indicator and the brake indicator light
at the same time.
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The 2 backup bulbs

The 4 stop/turn tail bulbs
The 1 CHMSL bulb
The 2 LH stop/turn/tail bulbs
The 2 right stop/turn/tail/bulbs
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Document ID: 455977
Page 1 of 2
Lighting Systems | Repair Instructions | Document ID: 455977
Headlamp Switch Replacement (Buick)

Removal Procedure
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement
3. Remove the fasteners (2) that retain the cover (1) to the inner side of the trim panel.
4. Remove the fasteners (3) that retain the switch to the trim panel.
5. Remove the switch.
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Document ID: 455977
Page 2 of 2
1. Install the switch.
2. Install the fasteners (3) that retain the switch to the trim panel.
3. Install the fasteners (2) that retain the cover (1) to the inner side of the trim panel.

5. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement
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Document ID: 404980
Page 1 of 1
Lamp Control Module Replacement

Removal Procedure
1. Remove the right closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side .
2. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side .
3. Slide the LCM to the left from the retainer while holding onto the lock tab.
1. Electrical connectors to the LCM.
2. Slide the LCM into the retainer, push to the right to engage.
3. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side .
4. Install the right closeout/insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Right Side .
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Document ID: 297896
Page 1 of 2
Headlamp Replacement (Buick)

Removal Procedure
1. Remove the 2 bolts (3) at the inboard edge of the headlamp (2).
2. Position the headlamp outboard in order to disengage the pins (1) at the rear of the
headlamp (2).
3. Remove the electrical connectors from the headlamp (2).
4. Remove the bulbs from the headlamp (2).
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1. Install the bulb to the headlamp (2).

2. Install the electrical connectors.
3. Position the headlamp inboard in order to engage the pins at the rear of the headlamp (2).
4. Install the 2 bolts (3) to the inboard edge of the headlamp (2).
Tighten
Tighten the bolts (3) to 5 Nm (44 lb in).
5. If you are installing a new headlamp (2), remove the horizontal aim adjuster restrictor from
the headlamp (2). Discard the horizontal aim adjuster restrictor.
6. Inspect the headlamp aim. Refer to Headlamp Aiming .
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Document ID: 297898
Page 1 of 3
Headlamp Aiming (Buick)

Properly aim the headlamps in order to obtain the maximum road illumination and safety built into
the headlamp system. Proper aiming is important with composite headlamps. Composite
headlamps increase the range and the power of the headlamps. Slight variations from the
recommended aiming may be hazardous to approaching motorists. Aiming after the bulb has been
replaced is not required with composite headlamps.
Ensure that the vehicle is at the normal weight regarding the following items when you inspect the
headlamp aim:
The fuel
The oil
The water
The spare tire
Inflate the tires uniformly to the specified pressure.
If the vehicle carries an unusual load in the rear compartment or a trailer, ensure that the load is
on the vehicle when you inspect the headlamps.
Follow all of the individual state requirements for headlamp aiming.
Inspect the headlamp aim when installing a new headlamp assembly. Inspect the headlamp aim if
service or repairs to the front end area may have disturbed the headlamps or the mountings.
The headlamp focus is set during the construction of the unit. Do not attempt to readjust the focus.
Follow all of the state laws and local laws for the proper requirements for the headlamp aim.
Adjust the horizontal aim using an adjusting screw on the outer side of the headlamp assembly.
Adjust the vertical aim using an adjusting screw in the top center of the assembly.
Perform the following steps in order to prepare the vehicle for aiming the headlamps:
1.
2.
3.
4.
5.
6.
7.
Completely assemble all of the components.

Place the vehicle on a level pad or surface.
Stop all unnecessary operations or work on the vehicle that affects the vehicle trim.
Close the doors.
Stabilize the suspension.
Ensure that the fuel level is at a 1/2 tank or less.
Ensure that the tires are inflated to the proper pressure.
Adjustment Procedure
Complete the following steps and refer to the accompanying illustrations in order to adjust the
headlamp aim:
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Document ID: 297898
Page 2 of 3
1. Ensure that the headlamps are a distance of 7.6 m (25 ft) away from the wall.
2. Mark a vertical line on the wall. Align the vertical line with the center line of the vehicle.
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3. Mark a horizontal line on the wall. Ensure that the distance of the line to the floor is equal to
2/7/2011
Document ID: 297898
Page 3 of 3
the distance from the center of the headlamp aim dot to the floor.
4. Using the following components, ensure that the following specifications match the
specifications in the illustrations:
The headlamp aim adjusters (1).
The zero set access hole (10).
The zero set meter (11).
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Document ID: 297901
Page 1 of 1
Fog Lamp Aiming

In order to prepare the vehicle for aiming the fog lamps, perform the following procedures:
1.
2.
3.
4.
5.
6.
7.
Completely assemble all of the components on the vehicle.

Position the vehicle on a level surface.
Stop all unnecessary operations or work on the vehicle that affects the vehicle trim.
Close the doors.
Stabilize the suspension.
Ensure that the fuel level is at a 1/2 tank or less.
Ensure that the tires are inflated to the proper pressure.
Vehicle Aim
Record the specification readings a distance of 7.6 m (25 ft) from the fog lamp lens in order to
perform the fog lamp vertical aim. Ensure that the top of the fog lamp beam is 50-150 mm (2-6 in)
below the fog lamp horizontal centerline.
Adjust the vertical aim by turning the vertical adjusting nut. The vertical adjusting nut is located on
the rear of the fog lamp assembly.
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Document ID: 297904
Page 1 of 2
Parking and Turn Signal Lamp Replacement

Removal Procedure
2. Remove the bolts (3) that retain the park/turn signal lamp (2) to the impact bar (1).
3. Remove the electrical bulb/socket from the park/turn signal lamp (2).
4. Remove the park/turn signal lamp (2).
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Document ID: 297904
1.
2.
3.
4.
Page 2 of 2
Install the electrical bulb/socket into the park/turn signal lamp (2).
Install the park/turn signal lamp (2).
Install the bolts (3) in order to retain the park/turn signal lamp (2) to the impact bar (1).
Lower the vehicle.
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2/7/2011
Document ID: 297906
Page 1 of 2
Park/Turn Signal/Side Marker Lamp Replacement

Removal Procedure
2. Remove the bulb/sockets from the lamp.
3. Remove the screws (3) that retain the lamp to the front bumper fascia (1).
4. Remove the front park/side marker lamp (2) from the fascia (1).
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Document ID: 297906
1.
2.
3.
4.
Page 2 of 2
Install the front park/side marker lamp (2) to the front bumper fascia (1).
Install the screws (3) in order to retain the lamp to the fascia (1).
Install the bulb/sockets to the lamp.
Lower the vehicle.
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2/7/2011
Document ID: 297908
Page 1 of 2
Cornering Lamp Replacement

Removal Procedure
1. Remove the headlamp. Refer to Headlamp Replacement .
2. Remove the screw (1) that retains the cornering lamp (2) to the fender.
3. Turn the socket counterclockwise in order to remove the socket from the cornering lamp (2).
4. Remove the cornering lamp (2).
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2/7/2011
Document ID: 297908
1.
2.
3.
4.
Install
Install
Install
Install
the
the
the
the
Page 2 of 2
socket to the cornering lamp (2).

cornering lamp (2) assembly.
screw (1) in order to retain the cornering lamp (2) to the fender.
headlamp. Refer to Headlamp Replacement .
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2/7/2011
Document ID: 297909
Page 1 of 2
High Mount Stop Lamp Replacement

Removal Procedure
1. Remove the rear seat. Refer to Rear Seat Back Replacement in Seats.
2.
3.
4.
5.
Remove
Remove
Remove
Remove
the
the
the
the
rear seat to window trim panel.

bolts (2) that retain the stoplamp to the trim panel.
electrical connector (3).
center high mounted stoplamp (1).
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Document ID: 297909
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1. Install the electrical connector (3) to the center high mounted stoplamp (1).
2. Install the stoplamp to the trim panel by sliding the lamp assembly rearward against the rear
window.
3. Install the bolts (2) in order to retain the stoplamp to the trim panel.
Tighten
Tighten the bolts (2) to 5 Nm (44 lb in). Tighten the bolts in the sequence shown in the
illustration.
4. Install the rear seat to rear window trim panel.
5. Install the rear seat. Refer to Rear Seat Back Replacement in Seats.
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2/7/2011
Document ID: 297910
Page 1 of 2
Backup Lamp Replacement (LeSabre)

Removal Procedure
1.
2.
3.
4.
5.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
caps covering the backup lamp retaining studs.

screws at the outer ends of the backup lamp assembly (2).
screws from the license plate pocket.
screws that retain the license plate lamps.
nuts (1) that retain the backup lamp assembly (2).
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Document ID: 297910
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1. Install the nuts (1) in order to retain the backup lamp assembly.
Tighten
2. Install the screws in order to retain the license plate lamps.
3. Install the screws in the license plate pocket.
Tighten
4. Install the screws to the outer ends of the backup lamp assembly (2).
Tighten
Important: Do not rework or alter the reflective surface of the taillamps.
5. Install the caps to the backup lamp retaining studs.
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Document ID: 297912
Page 1 of 2
Rear License Plate Lamp Replacement (LeSabre)

Removal Procedure
1. Remove the screws (2) that retain the license plate lamp (1).
2. Remove the bulb/socket (3) from the license lamp (1).
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Document ID: 297912
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1. Install the bulb/socket (3) to the license lamp (1).

2. Install the screws (2) in order to retain license plate lamp (1).
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Document ID: 297914
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Tail Lamp Replacement (LeSabre)

Removal Procedure
1. Remove the rear compartment sill panel trim. Refer to Rear Compartment Sill Trim Plate
Replacement .
2. Remove the nuts (1) that retain the taillamp (2).

3. Disconnect the lamp harness electrical connector.
4. Remove the taillamp (2).
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Document ID: 297914
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1. Install the taillamp (2).

2. Connect the lamp harness electrical connector.
Important: Do not rework or alter the reflective surface of the taillamps (2).
3. Install the nuts (1) in order to retain the taillamp (2).
Tighten
4. Install the rear compartment sill panel trim. Refer to Rear Compartment Sill Trim Plate
Replacement .
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Document ID: 297915
Page 1 of 2
Daytime Running Lamps (DRL) Resistor Replacement

Removal Procedure
1. Remove the air cleaner assembly.
2. Remove the PCM cover.
3. Remove the resistor screw (2-Buick,4-Pontiac/Oldsmobile) from the front fender.

4. Disconnect the connector.
5. Remove the daytime running lamp resistor (1-Pontiac/Oldsmobile,3-Buick).
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Document ID: 297915
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1. Connect the connector to the daytime running lamp resistor (1-Pontiac/Oldsmobile,3-Buick).

2. Connect the daytime running lamp resistor (1-Pontiac/Oldsmobile,3-Buick) to the front
fender.
3. Install the resistor screw (2-Buick,4-Pontiac/Oldsmobile) to the front fender.
Tighten
Tighten the screw (2-Buick,4-Pontiac/Oldsmobile) to 7 Nm (62 lb in).
4. Install the PCM cover.
5. Install the air cleaner assembly.
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Document ID: 297961
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Underhood Lamp Replacement

Removal Procedure
1. Disconnect the underhood lamp connector.

2. Remove the bolts that retain the underhood lamp (1) to the hood.
3. Remove the underhood lamp (1).
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1. Connect the connector to the underhood lamp (1).

2. Install the underhood lamp (1).
3. Install the bolts in order to retain the underhood lamp (1) to the hood.
Tighten
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Document ID: 298056
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Ashtray Lamp Bulb Replacement

Removal Procedure
1. Pull the ashtray up and out in order to remove the ashtray
2. Squeeze the tangs on each side of the bulb cover in order to remove the bulb cover.
Pull the bulb sideways in order to release the bulb.
Twist and pull the bulb cover in order to remove the bulb cover.
3. Pull outward on the bulb in order to remove the bulb.
1. Push the bulb into the socket.
2. Squeeze the tangs on both side of the bulb cover in order to install the cover.
Push the cover in order to secure the cover.
3. Push in and down on the ashtray in order to install the ashtray.
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Door Lamp Replacement

Removal Procedure

2. Remove the lamp housing. Insert a flat bladed tool under the forward edge of the housing to
depress the retaining clip.
4. Remove the bulbs as necessary. Pliers may be needed in order to rotate the bulbs out of the
housing.
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1.
2.
3.
4.
Page 2 of 2
Install the bulb holders and/or bulbs.

Snap the door lamp housing into the trim panel.
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Document ID: 298060
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Instrument Panel Courtesy Lamp Bulb Replacement

Removal Procedure
1. Pry the tangs outward at each end of the lens in order to remove the lens.
2. Pull the bulb outward in order to remove the bulb.
1. Push the bulb into the socket.
2. Press the lens into place.
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2/7/2011
Document ID: 298063
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Instrument Panel Compartment Lamp Replacement

Removal Procedure
1. Open the instrument panel compartment door.
2. Remove the lens by prying outward on the ends.
3. Pull the bulb rearward in order to remove the bulb.
1. Install the bulb by pushing the bulb into the socket.
2. Install the lens by pressing the corners of the lens into position.
3. Close the instrument panel compartment door.
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Document ID: 298066
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Ashtray Lamp Replacement

Removal Procedure
1. Pull the ashtray up and out in order to remove the ashtray.
2. Use the following procedures in order to remove the bulb cover:
2.1. Squeeze the tangs on each side of the bulb cover.
2.2. Pull the bulb cover sideways in order to release the bulb cover.
2.3. Twist and pull the bulb cover.
3. Pull outward in order to remove the bulb.
1.
2.
3.
4.
5.
Install the bulb by pushing the bulb into the socket.

Twist and push the bulb cover in order to install the bulb cover.
Squeeze the tangs on each side of the bulb cover.
Push the bulb cover in order secure the bulb cover.
Install the ashtray by pushing the ashtray in and down.
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Document ID: 298071
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Roof Rail Rear Courtesy Lamp Replacement

Removal Procedure
1. Remove the lens by prying outward on the ends.
2. Remove the bulb.
1. Install the bulb.
2. Install the lens by pressing on the ends in order to secure the lens.
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Document ID: 298074
Page 1 of 1
Vanity Mirror Lamp Replacement

Removal Procedure
1.
2.
3.
4.
Pull the sunshade downward.

Remove the lens by prying outward on the ends.
Remove the lens.
Remove the bulb from the vanity.
1. Install the bulb to the vanity.
2. Install the lens to the vanity by pressing the corners of the lens into position.
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Document ID: 298076
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Side Marker Lamp Replacement (Buick)

Removal Procedure
2. Turn the bulb/socket (4) counterclockwise in order to remove the socket from the side
marker lamp (1).
3. Remove the nuts (3) that retain the side marker lamp (1) to the rear bumper fascia (2).
4. Remove the side marker lamp (1).
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1.
2.
3.
4.
Page 2 of 2
Turn the bulb/socket (4) clockwise in order to install the socket to the side marker lamp (1).
Install the side marker lamp (1).
Install the nuts (3) in order to retain the side marker lamp (1) to the rear bumper fasica (2).
Lower the vehicle.
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2/7/2011
Document ID: 298079
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Rear Compartment Courtesy Lamp Replacement

Removal Procedure
1. Remove the rear compartment courtesy lamp (2) from the rear compartment lid by using
the following procedure:
1.1. Compress the tangs.
1.2. Pull the lamp through the cutout (1).
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Document ID: 298079
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1. Connect the electrical connector (3) to the rear compartment lid courtesy lamp (2).
2. Install the rear compartment courtesy lamp (2) by positioning the lamp assembly into the
cutout (1).
Apply pressure in order to secure the lamp.
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2/7/2011
Document ID: 344359
Page 1 of 1
Lighting Systems | Schematic and Routing Diagrams | Document ID: 344359
Cell 100: PWR, GND, RFA, Headlamp Switch and Headlamp

Dimmer Switch
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Document ID: 344382
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Cell 100: PNP Switch, Twilight Sentinal and Ambient Light

Sensor
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Document ID: 344386
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Cell 100: Headlamps and High Beam Indicator
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Document ID: 344481
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Cell 110: Headlamp Switch, RFA, and Park Lamp Control
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Document ID: 408249
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Cell 110: Turn/Hazard Switch and Stoplamp/BTSI Switch
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Document ID: 344828
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Cell 110: Front Park/Turn and Side Marker Lamps, Turn

Indicators
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Document ID: 344865
Page 1 of 1
Cell 110: Tail/Stop/Turn, Tail, and Rear Side Marker Lamps
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Document ID: 344823
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Cell 110: Cornering Lamps w/ T87
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Document ID: 344883
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Cell 112: PNP Switch, Backup Lamps, Perimeter Lighting Relay
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Document ID: 344888
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Cell 112: Perimeter Lighting Relay, RFA Module
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Document ID: 344891
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Cell 114: Interior Lamp Switch and Door Open Inputs
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Document ID: 344918
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Cell 114: Auxiliary Lighting Input, Underhood Lamp and

Ashtray Lamp
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Document ID: 344908
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Cell 114: Door and Foot Well Courtesy Lamps
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Document ID: 344901
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Cell 114: Dome/Reading Lamps
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Document ID: 344905
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Cell 114: Vanity Mirrors, IP Compartment Lamp and Console

Compartment Lamp
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Document ID: 344970
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Cell 117: Dimming Control and Incandescent Dimming
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Document ID: 344976
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Cell 117: VF Control, Incandescent Dimming (continued)
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2/7/2011
Document ID: 381303
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Brakes | Park Brake |

Specification
Application
Metric
English
Front Cable: Clip Bolt to Brake Pipe Retainer
6.0 Nm
53 lb in
Intermediate Cable: Retaining Nut at Underbody
22 Nm
16 lb ft
Parking Brake Lever Assembly Attaching Nut
27 Nm
20 lb ft
Parking Brake Switch Bolt
1.9 Nm
17 lb in
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Document ID: 381306
Page 1 of 4
Parking Brake Lever Pedal Assembly Replacement

Removal Procedure
1. Remove the lower I/P trim or the sound insulator panel as needed for access to the lever
assembly. Refer to Knee Bolster Replacement in Instrument Panel.
2. Disable the SIR system. Refer to Disabling the SIR System in (SIR) Restraints.
3. Remove the front parking brake cable (5) from the lever assembly after removing the
retaining clip.
4. Remove the electricalconnector

from
theCorporation.
parking brake
switch.
Motors
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reserved.
2011 General
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Document ID: 381306
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5. Remove the lever assembly attaching nuts.

6. Remove the lever assembly.
1. Install the lever assembly onto the dash panel studs.

surfaces unless specified. These coatings affect fastener torque and joint clamping tomsn048@gmail.com
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Document ID: 381306
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2. Install the two nuts at the upper rear locations and the nut at lower front location.
Tighten
3. Install the electrical connector to the parking brake switch.
4. Install the front parking brake cable at the lever assembly

5. Install the cable retaining clip (3).
6. Enable the SIR system. Refer to Enabling the SIR System in (SIR) Restraints.
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7. Install the I/P lower trim or the sound insulator panel. Refer to Knee Bolster Replacement in
Instrument Panel.
8. Adjust the parking brake cable. Refer to Park Brake Cable Service/Adjustment .
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Document ID: 388945
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Parking Brake Cable Inspection

1. If the parking brake is malfunctioning, check for the following conditions:
Parking brake cable sticking
Parking brake out of adjustment
Worn brake linings. Refer to Brake Shoe Inspection .
Grease or oil on linings. Refer to Brake Shoe Inspection .
Auto-adjuster malfunction. Refer to Brake Shoe Inspection .
2. Inspect the brake linings at regular intervals, and any time the wheels are removed (tire
rotation, etc.).
3. Replace the shoe and lining assemblies in the axle sets if the lining thickness is worn to
within 0.76 mm (1/32 in) of the shoe or rivet.
GM replacement brake lining material is recommended in order to maintain the balance between
front and rear brake performance. Installation of the brake lining material having characteristics
different from those of the recommended GM replacement parts can change the intended brake
balance of the vehicle.
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Document ID: 381313
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Parking Brake Front Cable Replacement

Removal Procedure
Information.
2. Loosen the adjuster (2).

3. Disconnect the front cable (3) from the adjuster (2).
4. Disconnect the cable retaining nut (1) at the underbody.
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6. Remove the cable (1) from the lever assembly.
1. Connect the cable to the lever assembly.

Information.
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procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener
joint
2/7/2011
Document ID: 381313
Page 3 of 3
3. Connect the cable retaining nut (1) at the underbody.
Tighten
Tighten nut to 22 Nm (16 lb ft).
4. Connect the front cable (3) to the adjuster (2).
5. Adjust the parking brake cable. Refer to Brake Shoe Inspection .
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Parking Brake Rear Cable Replacement

Removal Procedure
Information.
2. Loosen the adjuster nut (1) to release cable tension.

3. Mark the position of the wheel to the wheel studs in the bearing flange.
4. Remove the tire and the wheel. Mark the position of the brake drum to the wheel studs in the
bearing flange.
5. Remove the brake drum. Refer to Brake Drum Replacement in Drum Brakes..
6. Disconnect the parking brake cable from the parking brake lever. Refer to Parking Brake
Lever Pedal Assembly Replacement .
7. Depress the conduit fitting retaining tangs and remove the conduit fitting from the backing
plate.
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Document ID: 388961
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8. Disconnect the cable (1) from the equalizer (2).
9. Disconnect the cable (3) from the frame retaining hole (1).
10. Disconnect the cable from the rear park brake guide (2).
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1. Connect the cable through the rear park brake guide.

2. Install the cable (1) into the retaining hole and snap the cable into place.
3. Connect the cable (1) to the equalizer.

4. Install the conduit fitting into the backing plate.
5. Connect the parking brake cable to the parking brake lever. Refer to Parking Brake Lever
Pedal Assembly Replacement .
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6. Install the brake drum, the tire and the wheel.

Tighten
Tighten wheel nuts to 140 Nm (100 lb ft).
7. Adjust the parking brake cable. Refer to Park Brake Cable Inspection .
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Park Brake Cable Service/Adjustment

1. Adjust the rear brakes. Refer to Drum Brake Adjustment in Drum Brakes.
2. Apply the parking brake to six clicks and release. Repeat this apply/release step five times.
3. Check the parking brake pedal for full release by turning the ignition to ON and checking the
BRAKE warning lamp. The lamp should be off. If the lamp is on, verify that the pedal is in the
fully released position and pull downward on the front parking brake cable to remove the
slack.
4. Raise the vehicle and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
5. Remove the access hole plug in the rear brake backing plates.
6. Adjust the parking brake cable until a 1/8-inch drill bit (2) can be inserted through the access
hole into the space between the show web and the park brake lever (3). Satisfactory cable
adjustment is achieved when a 1/8-inch bit will fit into the space, but a 1/4-inch bit will not.
7. Apply the parking brake one click and check rear wheel rotation. When you try to rotate the
wheels by hand in a forward direction, the wheels should not move; in a rearward direction,
the wheels should drag or not move.
8. Release the parking brake and check for free wheel rotation.
9. Reinstall the access hole plugs.
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Document ID: 291539
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Steering |

Power Steering System | Specifications | Document ID: 291539

Specification
Application
Metric
English
Adjuster Plug Nut
70 Nm
50 lb ft
Cylinder End Fittings
27 Nm
20 lb ft
191 Nm
141 lb ft
Hexagon Jam Nut
68 Nm
50 lb ft
Hexagon Slotted Nut
47 Nm
35 lb ft
6 Nm
53 lb in
100 Nm
74 lb ft
Intermediate Steering Shaft Pinch Bolt
47 Nm
lb ft
Outer Hose Retaining Clamp Nuts
21 Nm
15 lb ft
Pinion Preload
1.8 Nm
16 lb ft
Power Steering Gear Hose Fittings to Pump and Steering Gear
27 Nm
20 lb ft
Power Steering Pump Mounting Bolts
27 Nm
20 lb ft
Steering Gear Mounting Bolts
65 Nm
48 lb ft
16.9 Nm
12.6 lb ft
Frame to Underbody Bolts
Inlet/Outlet Hose Retainer Bolts

Inner Tie Rod
Valve End Fitting
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Power Steering System | Visual Identification | Document ID: 423666
Power Steering Gear Disassembled View (Quiet Valve)

Quiet Valve Power Steering Gear
(1) Lubrication Fitting

(2) Hexagon Slotted Nut
(3) Cotter Pin
(4) Tie Rod Seal
(5) Outer Tie Rod
(6) Hexagon Jam Nut
(7) Tie Rod End Clamp
(8) Rack and Pinion Boot
(9) Large Boot Retaining Clamp
(10) Inner Tie Rod
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(11) Adjuster Plug Lock Nut

(12) Shock Dampener Ring
(13) Mounting Bracket Assembly
(14) Mounting Grommet
(15) Cylinder Line (LH)
(16) Cylinder Line (RH)
(17) O-ring Seal
(18) O-ring Seal
(19) Seal Adapter
(20) Retaining Ring
(21) Stub Shaft Seal
(22) Bearing Annulus Assembly
(23) Hexagon Lock Nut
(24) Dust Cover
(25) Rack and Pinion Gear Assembly (Partial)
(26) Shock Dampener Ring
(27) Inner Tie Rod
(28) Breather Tube
(29) Large Retaining Clamp
(30) Rack and Pinion Boot
(31) Tie Rod End Clamp
(32) Hexagon Jam Nut
(33) Outer Tie Rod
(34) Cotter Pin
(35) Hexagon Slotted Nut
(36) Tie Rod Seal
(37) Lubrication Fitting
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Document ID: 419450
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Power Steering System | Visual Identification | Document ID: 419450
Power Steering Pump Disassembled View (CB Series

Pump)
(1) Hydraulic Pump Reservoir Assembly (Typical)

(2) Reservoir Capstick Assembly
(3) O-Ring Seal
(4) Flow Control Spring
(5) Control Valve Assembly
(6) O-Ring Seal
(7) O-Ring Union Fitting
(8) Hydraulic Pump Housing Assembly
(9) Reservoir Retaining Clip (RH)
(10) Reservoir Retaining Clip (LH)
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Power Steering System | Repair Instructions | Document ID: 291555
Power Steering Pump Pulley Replacement

Removal Procedure
Tools Required
J 25034-C Pulley Remover
1. Remove the pump drive belts. Refer to Drive Belt Replacement in Engine Mechanical.
2. Remove the pump from the engine. Refer to Power Steering Pump Replacement .
3. Use the J 25034-C in order to remove the pulley from the pump.
Tools Required
J 25033-C Pulley Installer
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1. Use the J 25033-C in order to install the pulley onto the pump.
2. Axial tolerance of the pulley on the pump shaft is -0.25 mm to 0.25 mm (-0.010 in to
0.010 in).
3. Install the pump to the engine. Refer to Power Steering Pump Replacement .
4. Install the pump drive belt. Refer to Drive Belt Replacement in Engine Mechanical.
5. Bleed the power steering system.
6. Inspect the system for leaks.
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Power Steering Pump Replacement

Removal Procedure
1. Remove the following components as needed:

The strut housing upper tie bar nuts (1)
The strut housing upper tie bar
2. Remove the pump drive belt(s). Refer to Drive Belt Replacement in Engine Mechanical.
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3. Remove the lower bolt (3) from the mounting bracket.

4. Remove the following hoses (2) from the pump (1):
The power steering gear outlet hose
The power steering gear inlet hose
5. Remove the pump (1). On L36 and L67 engines, access the pump area from beneath the
engine.
6. Remove the transfer pulley, as needed.
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1. Hand-start the power steering gear inlet hose connection to the pump (1).
2. Install the lower bolt (3).
Hand tighten the lower bolt (3).
Important: Provide a clearance of 2-5 mm (0.080-0.200 in) between the hose and the
heater pipes. Contact may cause noise after the installation.
3. Connect the pump (1) with the pulley.
Important: Route the hose outboard and to the following places:
Under the engine harness
Under the heater hoses
4. Connect the power steering gear outlet hose (2) to the pump.
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Tighten
Tighten the power steering gear inlet hose (2) to pump, to 27 Nm (20 lb ft).
Tighten the hose clamp at the pump to 1.7 Nm (15 lb in).
Tighten the pump mounting bolts (3) to 30 Nm (22 lb ft).
5. Install the pump drive belt(s). Refer to Drive Belt Replacement in Engine Mechanical.
6. Install the following components, as needed:

The strut housing upper tie bar
The strut housing upper tie bar nuts (1)
Tighten
Tighten the nuts (1) to 25 Nm (18 lb ft).
7. Fill the system.
8. Bleed the system. Refer to Power Steering System Bleeding .
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Document ID: 419452
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Power Steering Fluid Reservoir Replacement - Off

Vehicle
1. Remove the retaining clips (1, 5) from the reservoir assembly (2) and the hydraulic pump
housing assembly (4).
2. Remove the reservoir (2) from the hydraulic pump housing assembly (4)
3. Remove the O-ring seal (3) from the hydraulic pump housing assembly (4).
4. Discard the O-ring seal (3).
Assembly Procedure
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Document ID: 419452
1.
2.
3.
4.
Page 2 of 2
Lubricate the new O-ring seal (3) with power steering fluid.
Install the O-ring seal (3) to the reservoir (2).
Install the reservoir assembly (2) to the hydraulic pump housing assembly (4).
Install the retaining clips (1, 5) to the reservoir (2) and to the hydraulic pump housing
assembly (4).
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Document ID: 419451
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Power Steering Pump Flow Control Valve Replacement

- Off Vehicle (CB Series)
1.
2.
3.
4.
Remove
Remove
Remove
Remove
the
the
the
the
O-ring union fitting (5) from the hydraulic pump housing assembly (1).
O-ring seal (4) from the O-ring union fitting (5).
control valve assembly (3).
flow control spring (2).
Assembly Procedure
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Document ID: 419451
1.
2.
3.
4.
Page 2 of 2
Install the flow control spring (2) to the hydraulic pump housing assembly (1).
Install the control valve assembly (3).
Lubricate the O-ring seal (4) with power steering fluid.
Install the O-ring seal (4) onto the O-ring union fitting (5).
Notice: Refer to Fastener Notice in the Preface section.
5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1).
Tighten
Tighten the fitting (5) to 75 Nm (55 lb ft).
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Checking and Adding Power Steering Fluid

Notice: When adding fluid or making a complete fluid change, always use a power steering fluid
meeting GM Spec. No. 9985010 or equivalent. Fluid for cold climates is also available through GM
Dealerships; refer to Specifications for further information. Failure to use the proper power steering
fluid can cause power steering hose and seal damage, fluid leaks and pump failure.
The power steering fluid level is indicated by marks on a fluid level indicator. The fluid level
indicator is located on the fluid reservoir capstick. Inspect the fluid level when the engine
compartment is cool. Ensure that the fluid level is at the FULL COLD mark. When the engine
compartment is hot, ensure that the level is at the HOT mark. Loosening or removing the capstick
when the engine compartment is hot relieves pressure in the power steering system. Pressure
contributes to a quiet system.
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Document ID: 487449
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Power Steering System Bleeding

Important:
Use clean, new power steering fluid type only. See the Maintenance and Lubrication
subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations .
Hoses touching the frame, body or engine may cause system noise. Verify that the
hoses do not touch any other part of the vehicle.
Loose connections may not leak, but could allow air into the steering system. Verify that
all hose connections are tight.
Important: Power steering fluid level must be maintained throughout bleed procedure.
1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash
mark on cap stick fluid level indicator.
Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost
accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will
discharge the hydro-boost accumulator.
2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following
procedure:
2.1. Start the engine.
2.2. Firmly apply the brake pedal 10-15 times.
2.3. Turn the engine OFF.
3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the
Vehicle in General Information.
4. Key on engine OFF, turn the steering wheel from stop to stop 12 times.
Vehicles equipped with hydro-boost systems or longer length power steering hoses may
require turns up to 15 to 20 stop to stops.
5. Verify power steering fluid level per operating specification. Refer to Checking and Adding
Power Steering Fluid .
6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid
aeration (pump noise/whining).
7. Verify the fluid level. Repeat the bleed procedure if necessary.
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Power Steering System Flushing

1. Raise the front end of the vehicle until the wheels are free to turn. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the power steering gear outlet hose from the pump reservoir inlet connector.
Remove the plug inlet connector port on the reservoir. Refer to Power Steering Hoses
Replacement .
3. Place the end of the return line into a large container in order to catch the fluid that drains
from the system.
4. Ask an assistant to fill the reservoir with new power steering fluid.
Maintain the level at the FULL COLD mark while flushing the system.
5. Start the engine.
6. Run the engine at idle speed.
Notice: Do not hold the steering wheel against the stops while flushing the power steering
system. Holding the steering wheel against the wheel stops will cause high system pressure,
overheating, and damage to the power steering pump and/or gear.
7. Turn the steering wheel from stop to stop.
Important: Do NOT re-use any drained power steering fluid.
8. Continue to drain and flush the system until all of the old fluid is cleared from the system.
Add approximately 0.9 liter (1 quart) of new fluid in order to complete the flushing
procedure.
9. When you have completed the flushing procedure, perform the following additional steps:
9.1. Stop the engine.
9.2. Unplug the reservoir inlet port.
9.3. Reconnect the return line.
10. Fill the reservoir to the FULL COLD level.
11. Bleed the power steering system. Refer to Power Steering System Bleeding .
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Power Steering Hoses Replacement

Removal Procedure

The retainer (6)
The shield (8)
2. Remove the clamps (3) or connections at the gear.
3. Remove the clamps (3) or connections at the pump.
4. Remove the hoses (2,4).
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1. Install the hoses (2,4).

2. Install the clamps (3) or connections at the gear.
3. Install the clamps (3) or connections at the pump.
The retainer (6)
The shield (8)
Tighten
Tighten the retainer (6) and the shield (8) mounting bolts (7) to 8 Nm (71 lb in).
Tighten the power steering gear inlet hose (4) to pump to 27 Nm (20 lb ft).
Tighten the hose clamp (3) at the pump to 1.7 Nm (15 lb in).
Tighten the power steering gear outlet (2) and the power steering inlet hose (4) to
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Document ID: 291563
Page 3 of 3
5. Fill the system.

6. Bleed the system. Refer to Power Steering System Bleeding .
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Document ID: 585142
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Steering Linkage Outer Tie Rod Replacement

Removal Procedure
Tools Required
J 24319-01 Universal Steering Linkage Puller
1. Remove the cotter pin (2) and the hex slotted nut (1) from the outer tie rod assembly.
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Document ID: 585142
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2. Loosen the jam nut (2) on the inner tie rod assembly (1).
3. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01 .
4. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1).
1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam nut
(2).
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2. Connect the outer tie rod assembly (2) to the steering knuckle (1).
Important: Align the cotter pin slot by tightening the hex slotted nut (1) up to 1/6
additional turn, or 70 Nm (52 lb ft) maximum. Do not back off the hex slotted nut (1) for the
cotter pin insertion.
3. Connect the hex slotted nut (1) to the outer tie rod stud (3).
Tighten
Tighten the hex slotted nut (1) to 47 Nm (35 lb ft).
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4. Install the cotter pin (2) into the hole in the tie rod stud.
Important: Be sure the rack and pinion boot is not twisted or puckered during toe
adjustment.
5. Adjust the toe alignment. Refer to Front Toe Adjustment in Wheel Alignment.
Tighten
Tighten the jam nut against the outer tie rod to 68 Nm (50 lb ft).
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Document ID: 424138
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Steering Gear Boot Replacement - Off Vehicle

Tools Required
J 22610 Service Boot Clamp Installer
1. To remove the outer tie rod; refer to Rack and Pinion Outer Tie Rod End Replacement .
2. Remove the hex jam nut (2) from the inner tie rod assembly (1).
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Document ID: 424138
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3. Remove the tie rod end clamp (2) from the rack and pinion boot (1).
4. Remove the boot clamp (1) from the rack and pinion boot with side cutters.
5. Discard the boot clamp (1).
Important: Prior to removing the breather tube or the rack and pinion boot, mark the
location of the breather tube on the gear assembly.
6. Remove the rack and pinion boot (1) and the breather tube from the rack and pinion gear
assembly.
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Assembly Procedure
Tools Required
1. Install the new boot clamp (2) onto the rack and pinion boot (1).
2. Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and
the rack and pinion gear assembly (1).
3. Install the rack and pinion boot (3) onto the inner tie rod assembly (2).
4. Install the breather tube while aligning the breather tube with the mark made during removal
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Document ID: 424138
Page 4 of 5
and the molded nipple of the rack and pinion boot.

Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in
any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion
boot (3) by hand before installing the boot clamp.
5. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3)
is seated in the gear assembly groove.
6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610 .
7. Crimp the boot clamp (1).
8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end
clamp.
9. Install the hex jam nut (2) to the inner tie rod assembly (1).
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10. To assemble the outer tie rod assembly; refer to Rack and Pinion Outer Tie Rod End
Replacement .
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Document ID: 291565
Page 1 of 3

Steering Gear Replacement

Removal Procedure
Tools Required
J 24319-B Puller
1. Raise and support the vehicle with a suspension contact hoist. Refer to Lifting and Jacking
the Vehicle in General Information.
2. Remove both front tires and wheels.
Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can
result in damage to the steering gear and/or intermediate shaft. This damage can cause loss
of steering control which could result in personal injury.
Notice: The wheels of the vehicle must be straight ahead and the steering column in the
LOCK position before disconnecting the steering column or intermediate shaft from the
steering gear. Failure to do so will cause the coil assembly in the steering column to become
uncentered which will cause damage to the coil assembly.
3. Remove the intermediate shaft lower connection.
4. Use the J 24319-B in order to remove the tie rod ends from the steering knuckles.
5. Remove the power steering gear outlet and inlet hoses from the steering gear. Refer to
Power Steering Hoses Replacement .
6. Remove the steering gear mounting bolts.
Notice: Do not lower the rear of the frame too far as damage to the engine components
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Document ID: 291565
Page 2 of 3
nearest to the cowl may result.

7. Remove the steering gear through the wheel opening.
1. Install the steering gear through the wheel opening.
2. Raise the rear of the frame.
3. Install the frame bolts. Refer to Frame in Body Front End.
Tighten
Tighten the frame bolts to 103 Nm (76 lb ft).
4. Remove the stands.

The 5 steering gear mounting bolts
The 2 washers
Tighten
1. Tighten the bolts in the sequence shown in the illustration.
2. Tighten the bolts to 68 Nm (50 lb ft). Use Loctite Tread Locking Kit No. 105264, or
the equivalent.
6.
Install
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Document ID: 291565
Page 3 of 3
Replacement .
Tighten
Tighten the hose connections to 27 Nm (20 lb ft).
7. Install the retainer.
8. Connect the tie rod ends to the steering knuckles.
Tighten
Tighten the tie rod end nuts to 47 Nm (35 lb ft).
9. Install the cotter pin.
Tighten
Tighten the nut up to an additional 1/6 turn, or to a maximum of 70 Nm (52 lb ft) in order to
align the cotter pin slot. Do not back off the nut for the cotter pin insertion.
10. Install the intermediate steering shaft pinch bolt.
Tighten
Tighten the intermediate steering shaft pinch bolt to 47 Nm (35 lb ft).
11. Install the tires and wheels.
Tighten
12.
13.
14.
15.
Lower the vehicle.

Fill the system.
Bleed the system. Refer to Power Steering System Bleeding .
Inspect the system for leaks.
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Document ID: 423709
Page 1 of 1

Steering Gear Rack Bearing Preload Adjustment - Off

Vehicle (Quiet Valve)
1.
2.
3.
4.
Loosen the adjuster plug lock nut (1).

Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly.
Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat).
Install the adjuster plug lock nut (1) to the adjuster plug.
Tighten
Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) 68 Nm
(50 lb ft).
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Document ID: 423716
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Steering Gear Rack Bearing Preload Adjustment - Off

Vehicle (Adjust Magna Valve)
1.
2.
3.
4.
Loosen the adjuster plug lock nut (1).

Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly.
Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat).
Install the adjuster plug lock nut (1) to the adjuster plug.
Tighten
Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) 68 Nm
(50 lb ft).
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Page 1 of 4

Steering Gear Boot and Breather Tube Replacement Off Vehicle (Quiet Valve)
Tools Required
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Document ID: 423777
Page 2 of 4
4. Remove the boot clamp (1) from the rack and pinion boot (3) with side cutters.
5. Discard the boot clamp (1).
Important: Prior to removing the breather tube (2) or the rack and pinion boot (3), mark
the location of the breather tube (2) on the gear assembly.
6. Remove the rack and pinion boot (3) and the breather tube (2).
Assembly Procedure
Tools Required
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Document ID: 423777
Page 3 of 4
4. Align the breather tube with the mark made during removal and the molded nipple of the
rack and pinion boot.
5. Install the rack and pinion boot (3) onto the gear assembly until the rack and pinion boot (3)
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Document ID: 423777
Page 4 of 4
boot (3) by hand before installing the boot clamp.
clamp.
Replacement .
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Document ID: 445542
Page 1 of 5

Steering Gear Boot and Breather Tube Replacement Off Vehicle (Magnasteer)
Tools Required
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Document ID: 445542
Page 2 of 5
4. Remove the boot clamp (1) from the rack and pinion boot with side cutters.
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Document ID: 445542
5.
6.
7.
8.
9.
10.
Page 3 of 5
Remove the rack and pinion boot (1) from the rack and pinion gear assembly.
Discard the boot clamp.
Inspect the rack and pinion boot (1) for damage.
Look for gear oil leakage inside the rack and pinion boot (1).
Drain the oil.
Clean the rack and pinion boot (1) with solvent.
Assembly Procedure
Tools Required
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Document ID: 445542
Page 4 of 5
boot by hand before installing the boot clamp.
4. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3)
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Document ID: 445542
Page 5 of 5
clamp.
Replacement .
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Document ID: 423747
Page 1 of 3

Steering Gear Cylinder Pipe Assembly and Seals

Replacement - Off Vehicle (Magna Valve)
1. Loosen both cylinder line fittings (1) on the cylinder end of the gear assembly.
2. Loosen both fittings on the cylinder line assemblies (3) at the valve end of the gear
assembly.
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Document ID: 423747
Page 2 of 3
3. Remove both cylinder line assemblies (1) from the rack and pinion gear assembly (2).
4. Remove the O-ring seals (1) from the valve end of line.
5. Discard the O-ring seals (1).
Assembly Procedure
1. Inspect the cylinder lines (1) for the following items:

Cracks
Dents
Damage to the threads
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2. Replace the parts as needed.
Document ID: 423747
Page 3 of 3
3. Install the new O-ring seals (1) to the valve end of the cylinder lines.
4. Install the cylinder line assemblies (1) to the gear assembly (2).
Tighten
Valve end fittings to 16.9 Nm (12.6 lb ft). Cylinder end fittings to 27 Nm (20 lb ft).
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Document ID: 423751
Page 1 of 3

Steering Gear Cylinder Pipe Assembly and Seals

Replacement - Off Vehicle (Quiet Valve)
1. Loosen both cylinder line fittings (1) on the cylinder end of the gear assembly.
2. Loosen both fittings on the cylinder line assemblies (3) at the valve end of the gear
assembly.
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Document ID: 423751
Page 2 of 3
3. Remove both cylinder line assemblies (1) from the rack and pinion gear assembly (2).
4. Remove the O-ring seals (1) from the valve end of line.
5. Discard the O-ring seals (1).
Assembly Procedure
1. Inspect the cylinder lines (1) for the following items:

Cracks
Dents
Damage to the threads
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2. Replace the parts as needed.
Document ID: 423751
Page 3 of 3
3. Install the new O-ring seals (1) to the valve end of the cylinder lines.
4. Install the cylinder line assemblies (1) to the gear assembly (2).
Tighten
Valve end fittings to 16.9 Nm (12.6 lb ft). Cylinder end fittings to 27 Nm (20 lb ft).
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Document ID: 423769
Page 1 of 4

Steering Linkage Outer Tie Rod Replacement

Tools Required
1. Pull the cotter pin (3) and the hex slotted nut (2) from outer tie rod assembly (1).
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Document ID: 423769
Page 2 of 4
2. Loosen the jam nut (2) on the inner tie rod assembly (1).
3. Remove the outer tie rod assembly (2) from the steering knuckle (1) using J 24319-01 .
4. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1).
Assembly Procedure
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Document ID: 423769
Page 3 of 4
1. Connect the outer tie rod assembly (3) to the inner tie rod (1). Do not tighten the jam
nut (2).
2. Connect the outer tie rod assembly (2) to the steering knuckle (1).
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Document ID: 423769
Page 4 of 4
3. Connect the hex slotted nut (2) to the outer tie rod stud (1).
Tighten
Tighten the hex slotted nut (2) to 47 Nm (35 lb ft). Align the cotter pin slot by tightening the
hex slotted nut (2) up to 1/6 additional turn, or 70 Nm (52 lb ft) maximum. Do not back off
the hex slotted nut (2) for the cotter pin (3) insertion.
4. Install the cotter pin (3) into the hole in the tie rod stud.
Tighten
Tighten the hex jam nut against the outer tie rod to 68 Nm (50 lb ft).
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Document ID: 423786
Page 1 of 4

Steering Linkage Inner Tie Rod Replacement (Quiet

Valve)
1. To remove the rack and pinion boot and the breather tube; refer to Steering Gear Boot and
Breather Tube Replacement - Off Vehicle .
2. Remove the shock dampener (2) from the inner tie rod assembly (5).
3. Slide the shock dampener (2) back on the rack (1).
4. Remove the inner tie rod assembly (5) from the rack assembly (1) as follows:
3.1. Place a wrench on flats of rack assembly (3).
3.2. Place another wrench on the flats of the inner tie rod housing (4).
3.3. Rotate the inner tie rod housing (4) counterclockwise until the inner tie rod (5)
separates from the rack (1).
Assembly Procedure
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Document ID: 423786
Page 2 of 4
1. Slide the shock dampener (2) forward onto the rack (1).
2. Attach the inner tie rod (6) on the rack (1) as follows:
2.1. Place a wrench on the flats of the rack assembly (3).
2.2. Place a torque wrench (5) on the flats of the inner tie rod housing (4).
Tighten
Inner tie rod to 100 Nm (74 lb ft).
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Document ID: 423786
Page 3 of 4
3. Place the inner tie rod assembly (2) in a vise.

4. Stake both sides of the inner tie rod assembly to the flats on the rack (1).
5. Insert a 0.25 mm gauge (1) between the rack (2) and the inner tie rod housing (3) in order
to check both stakes. The feeler gauge (1) must not pass between the rack and the housing
stake.
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Document ID: 423786
Page 4 of 4
6. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the
shock dampener (2) bottoms against the inner tie rod housing (3).
7. To assemble the rack and pinion boot and the breather tube; refer to Steering Gear Boot and
tomsn048@gmail.com
Document ID: 445563
Page 1 of 4

Steering Linkage Inner Tie Rod Replacement

(Magnasteer With Breather Tube)
1. To remove the rack and pinion boot and the breather tube; refer to Steering Gear Boot and
2. Remove the shock dampener (2) from the inner tie rod assembly (5).
3. Slide the shock dampener (2) back on the rack (1).
4. Remove the inner tie rod assembly (5) from the rack assembly (1) as follows:
3.1. Place a wrench on flats of rack assembly (3).
3.2. Place another wrench on the flats of the inner tie rod housing (4).
3.3. Rotate the inner tie rod housing (4) counterclockwise until the inner tie rod (5)
separates from the rack (1).
Assembly Procedure
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Document ID: 445563
Page 2 of 4
1. Slide the shock dampener (2) forward onto the rack (1).
2. Attach the inner tie rod (6) on the rack (1) as follows:
2.1. Place a wrench on the flats of the rack assembly (3).
2.2. Place a torque wrench (5) on the flats of the inner tie rod housing (4).
Tighten
Inner tie rod to 100 Nm (74 lb ft).
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Document ID: 445563
Page 3 of 4
3. Place the inner tie rod assembly (2) in a vise.

4. Stake both sides of the inner tie rod assembly to the flats on the rack (1).
5. Insert a 0.25 mm gauge (1) between the rack (2) and the inner tie rod housing (3) in order
to check both stakes. The feeler gauge (1) must not pass between the rack and the housing
stake.
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Document ID: 445563
Page 4 of 4
6. Slide the shock dampener (2) over the inner tie rod housing (3) until the front lip of the
shock dampener (2) bottoms against the inner tie rod housing (3).
7. To assemble the rack and pinion boot and the breather tube; refer to Steering Gear Boot and
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Document ID: 423798
Page 1 of 6

Steering Gear Stub Shaft Seal and Bearing Replacement

1. Remove the adjuster plug lock nut (5) from the adjuster plug (4).
2. Remove the adjuster plug (4) from the gear assembly (1).
3. Remove the adjuster spring (3) and the rack bearing (2).
4. Remove the retaining ring (1) from the valve bore of the rack and pinion gear assembly (2).
5. Remove the dust cover
(4) from
the
bottom
of the rack
andreserved.
pinion gear assembly (2).
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General
Motors
Corporation.
All rights
2010
Document ID: 423798
Page 2 of 6
6. Remove the hex lock nut (3) from the lower end of the pinion and valve assembly while
holding the stub shaft with a 14 mm crowfoot wrench.
Important: When performing the following procedure, do not remove pinion and valve
assembly from the rack and pinion gear assembly (5). Press the pinion and valve assembly
only far enough to allow removal of the stub shaft bearing annulus (3) and the stub shaft
seal (2).
7. Using an arbor press (1), press on the threaded end of the pinion until removal of the
following items is possible:
7.1. The stub shaft (4)
7.2. The stub shaft seal (2)
7.3. The stub shaft bearing annulus assembly (3)
Assembly Procedure
Tools Required
J 6222-A Stub Shaft Seal Protector
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Document ID: 423798
Page 3 of 6
1. Install the hex lock nut (1) onto the pinion while holding the valve stub shaft.
Tighten
Tighten the hex lock nut (1) to 30 Nm (22 lb ft).
2. Install the dust cover (2) to the rack and pinion gear assembly.
3. Install the stub shaft bearing annulus assembly (1) onto the valve stub shaft (2).
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Document ID: 423798
4.
5.
6.
7.
Page 4 of 6
Install J 6222-A onto the valve stub shaft.

Lubricate the stub shaft seal (2) with grease.
Install the stub shaft seal (2) into the rack and pinion gear assembly.
Install the retaining ring (1) into the groove in the rack and pinion gear assembly.
8. Lubricate the following items with lithium base grease:

8.1. The rack bearing (2)
8.2. The adjuster spring (3)
8.3. The adjuster plug (4)
9. Install the following items into the gear assembly:
9.1. The rack bearing (2)
9.2. The adjuster spring (3)
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Document ID: 423798
Page 5 of 6
9.3. The adjuster plug (4)
10. Turn the adjuster plug (1) clockwise onto the rack and pinion gear assembly until the
adjuster plug (1) bottoms in the rack and pinion gear assembly, then turn the adjuster
plug (1) back 50 degrees to 70 degrees.
11. Check the rotational torque on the pinion. The maximum pinion preload torque is 1.8 Nm
(16 lb in).
12. Install the adjuster plug lock nut (5) to the adjuster plug (4).
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Document ID: 423798
Page 6 of 6
Tighten
Finger tighten the adjuster plug lock nut (5) while holding the adjuster plug (4) stationary.
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Document ID: 395790
Page 1 of 1

Real Time Damping (RTD) | Schematic and Routing Diagrams | Document ID: 395790
Cell 43: CCR Power and Grounds
2/7/2011
Document ID: 395793
Page 1 of 1

Cell 43: Shift Select Switch
2/7/2011
Document ID: 395794
Page 1 of 1

Cell 43: Strut Actuators
2/7/2011
Document ID: 228497
Page 1 of 1

Real Time Damping (RTD) | Component Locator | Document ID: 228497
Passenger Compartment, Under LH Seat
(1) Computer Command Ride (CCR) Control Module

(2) Lateral Accelerometer
2/7/2011
Document ID: 343265
Page 1 of 1

Engine Compartment, Left Rear Corner
(1) P100 (Hidden)

(2) LH Front Strut Tower
(3) LH Front Strut Actuator (RH Similar)
2/7/2011
Document ID: 400546
Page 1 of 1

Passenger Compartment, Rear Package Shelf Area
(1) RH Rear Strut Tower -- LH Similar

(2) RH Rear Strut Actuator -- LH Similar (Pontiac w/FW1)
(3) RH Rear Speaker
(4) LH Rear Speaker
(5) P408
(6) S301
(7) P400
2/7/2011
Document ID: 400489
Page 1 of 1

Passenger Compartment, In the Console (Pontiac)
(1) Shift Select Switch

(2) Seat Switches
(3) Rear Console Cigar Lighter
(4) Shifter
2/7/2011
Document ID: 395830
Page 1 of 6

Suspension Controls Connector End Views

Table 1:
Lateral Accelerometer
Table 2:
LH Front Strut Actuator
Table 3:
LH Rear Strut Actuator
Table 4:
RH Front Strut Actuator
Table 5:
RH Rear Strut Actuator
Table 6:
Shift Select Switch C2 (Pontiac)
Electronic Suspension Control (CCR) Module
Connector Part
Information
12045537
32 Way F Micro-Pack 100 Series (GRY)
Pin
Wire Color
Circuit
No.
C1
C2
DK BLU
1308
CCR Module Lateral Acceleration Signal Output
C3
PPL/WHT
1490
CCR Module Signal - WOT
C4
C5
LT GRN
1435
CCR Switch Signal (Normal)
C6
BRN/WHT
1434
CCR Signal Switch (Firm)
C7
DK GRN/WHT
817
C8
C9
DK GRN
1437
CCR LED Feed (Firm)
C10
PNK
1438
CCR LED Feed (Normal)
C11- C12
C13
WHT/BLK
1006
RH Front Ride Control Strut Motor Feed

(Increase)
C14
YEL
1014
RH Rear Ride Control Strut Motor Feed (Increase)
C15
Function
Not Used
Not Used

Not Used
Not Used
LT BLU 2011 General

1770 Motors
Ride
Control Diagnostic
Signal
Corporation.
2/7/2011
Document ID: 395830
Page 2 of 6
C16
BRN
641
Fused Output (Ign)
D1
BLK/WHT
251
Ground
D2
LT GRN
1826
Ride Control Diagnostic Enable Signal
D3
DK GRN/WHT
1016
RH Rear CCR Strut Position Signal
D4
BRN/WHT
1012
LH Rear CCR Strut Position Signal
D5
LT BLU
1008
RH Front CCR Strut Position Signal
D6
BRN/WHT
1004
LH Front CCR Strut Position Signal
D7
GRY
1309
CCR Module Lateral Acceleration Signal Input
D8
BRN
1009
RH Front Ride Control Strut Motor Feed

(Decrease)
D9
PPL
1017
RH Rear Ride Control Strut Motor Feed

(Decrease)
D10
LT GRN
1005
LH Front Ride Control Strut Motor Feed

(Decrease)
D11
RED/BLK
1013
LH Rear Ride Control Strut Motor Feed

(Decrease)
D12
D13
RED
1448
LH Front Ride Control Strut Motor Feed

(Increase)
D14
RED
1010
LH Rear Ride Control Strut Motor Feed (Increase)
D15
D16
BLK/WHT
251
Not Used
Not Used
Ground
Lateral Accelerometer
Connector Part
Information
12052635
Pin
Wire Color
Circuit
No.
DK BLU
13018
Computer Command Ride Module Lateral Acceleration

Signal - Output
GRA
1309
Computer Command Ride Module Lateral Acceleration
Function
2/7/2011
Document ID: 395830
Page 3 of 6
Signal - Input
LH Front Strut Actuator
Connector Part
Information
12129129
3-Way F P25 (MD GRA)
Pin
Wire Color
Circuit
No.
RED
1448
Ride Control Strut Motor Feed - Left Front Increase

Damping
BRN/WHT
1004
Computer Command Ride Strut Position Signal - Left

Front
LT GRN
1005
Ride Control Strut Motor Feed - Left Front Decrease

Damping
Function
LH Rear Strut Actuator
Connector Part
Information
Pin
Wire Color
12129129
Circuit
No.
Function
2/7/2011
Document ID: 395830
Page 4 of 6
RED
1010
Ride Control Strut Motor Feed - Left Rear Increase

Damping
BRN/WHT
1012
Computer Command Ride Strut Position Signal - Left

Rear
RED/BLK
1013
Ride Control Strut Motor Feed - Left Rear Decrease

Damping
RH Front Strut Actuator
Connector Part
Information
12129129
Pin
Wire Color
Circuit
No.
WHT/ BLK
1006
Ride Control Strut Motor Feed - Right Front Increase

Damping
LT BLU
1008
Computer Command Ride Strut Position Signal Right Front
BRN
1009
Ride Control Strut Motor Feed - Right Front Decrease

Damping
Function
RH Rear Strut Actuator
2/7/2011
Document ID: 395830
Connector Part
Information
Page 5 of 6
12129129
Pin
Wire Color
Circuit
No.
YEL
1014
Ride Control Strut Motor Feed - Right Rear Increase

Damping
DK GRN/WHT
1016
Computer Command Ride Strut Position Signal Right Rear
PPL
1017
Ride Control Strut Motor Feed - Right Rear Decrease

Damping
Function
Shift Select Switch Connector C1 (Pontiac)
Connector Part
Information
12047886
Pin
Wire Color
Circuit
No.
BRN
1141
Fused Output - IGN3
BRN/WHT
1571
Traction Control Switch Signal
BLK/WHT
251
DK BLU
1660
GRY
BLK
1250
LT BLU
553
Transmission Shift Select Switch Output Performance
BLK
808
Sensor Ground
Function
Ground
Tracton Control Indicator Lamp Driver Module
Output
Ground
Shift Select Switch C2 (Pontiac)
2/7/2011
Document ID: 395830
Connector Part
Information
Page 6 of 6
12047785
Pin
Wire Color
Circuit
No.
PNK
1438
Computer Command Ride LED Feed - Normal
DK GRN
1437
Computer Command Ride LED Feed - Firm
LT GRN
1435
Computer Command Ride Switch Signal Normal
BRN/WHT
1434
Computer Command Ride Switch Signal - Firm
Function
2/7/2011
Document ID: 529957
Page 1 of 2

Real Time Damping (RTD) | Repair Instructions | Document ID: 529957
Vehicle Lateral Accelerometer Replacement

Removal Procedure
1.
2.
3.
4.
Remove the driver's seat. Refer to Seat Replacement .

Pull the carpet back to expose the lateral accelerator switch.
Disconnect the electrical connector from the lateral accelerator switch.
Remove the two screws and the lateral accelerator switch.
1. Install the lateral accelerator switch with two screws.
Tighten
Tighten the screws to 2 Nm (18 lb in)
2/7/2011
Document ID: 529957
Page 2 of 2
2. Connect the electrical connector to the module.

3. Install the carpet.
4. Install the driver's seat. Refer to Seat Replacement .
2/7/2011
Document ID: 529963
Page 1 of 2

Real Time Damping (RTD) | Repair Instructions | Document ID: 529963
Electronic Suspension Control Module Replacement

Removal Procedure
1. Remove the driver's seat. Refer to Seat Replacement .
2. Pull the carpet back to expose the control module.
3. Disconnect the electrical connector from the control module.

4. Remove the two screws and the control module.
1. Install the control module with two screws.
Tighten
Tighten the screws to 2 Nm (18 lb in)
2/7/2011
Document ID: 529963
Page 2 of 2
2. Connect the electrical connector to the module.

3. Install the carpet.
4. Install the driver's seat. Refer to Seat Replacement .
2/7/2011
Document ID: 360128
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Suspension | Rear Suspension |

Specification
Application
Metric
English
Adjustment Link Lock Nut
65 Nm
48 lb ft
Adjustment Link to Control Arm
85 Nm
63 lb ft
Adjustment Link to Knuckle
45 Nm
33 lb ft
Ball Joint
55 Nm
40 lb ft
Control Arms Nuts (Optional Torque)
182 Nm
134 lb ft
Control Arms Nuts
115 Nm
85 lb ft
Hub and Bearing Bolts
70 Nm
52 lb ft
Stabalizer Shaft Insulator Link Bolt
23 Nm
17 lb ft
Stabalizer Shaft Link Nut (at Bracket)
17 Nm
13 lb ft
Stabalizer Shaft Link Assembly
47 Nm
35 lb ft
Stabalizer Shaft Mounting Bracket to Body
18 Nm
14 lb ft
190 Nm
140 lb ft
47 Nm
35 lb ft
Strut to Knuckle
Strut (Tower) Mounting Nut
2/7/2011
Document ID: 360130
Page 1 of 2
Rear Wheel Bearing and Hub Replacement

Removal Procedure
Information.
Notice: Do not hammer on brake drum as damage to the bearing could result.
3. Remove the brake drum (2). Refer to Brake Drum Replacement in Drum Brakes.
4. Remove the ABS sensor wire connector.
Important: The bolts which attach the hub and the bearing also support the brake
assembly. When removing these bolts, support the brake assembly with a wire or by other
means. Do not let the brake line or the ABS electrical wire support the brake assembly.
5. Remove the four bolts (1), the hub (3), and the bearing from the axle.
6. Clean the knuckle face and the bore before installing the hub and the bearing.
Installation
2/7/2011
Document ID: 360130
Page 2 of 2
1. Install the hub and the bearing (3) to the rear knuckle with four bolts (1). Be careful not to
drop the hub and the bearing, as it could cause damage.
2. Reconnect the ABS sensor.
Tighten
Tighten the hub and the bearing bolts to 70 Nm (52 lb ft).
3. Install the brake drum (2). Refer to Brake Drum Replacement in Drum Brakes.
4. Install the wheel and the tire.
Tighten
2/7/2011
Document ID: 167983
Page 1 of 1
Ball Joint Inspection
When checking the condition of the ball joint, be sure to follow the inspection procedure closely to
prevent unnecessary ball joint replacement. During the inspection, have the vehicle supported by
the wheels to insure that its weight is the loading ball joints.
The ball joint has a visual wear indicator. Wear is indicated by a 13 mm (0.50 in) diameter nipple
retracting into the ball joint cover (the ball joint grease fitting is threaded into this nipple). The
nipple protrudes 1.27 mm (0.050 in) (1) beyond the ball joint cover surface (3) on a new, unworn
joint. Replace the ball joint if the nipple is flush or below the cover surface (2).
As part of the inspection, check the ball stud tightness in the knuckle boss. Check it by shaking the
wheel and feeling for movement of the stud end or castellated nut at the knuckle boss. Checking
the fastener tightness at the castellated nut is an alternative method of inspecting. A loose nut can
indicate a bent stud or an opened-up hole in the knuckle boss. If worn, replace the ball joint and
the knuckle.
If the ball joint is separated from the knuckle for suspension service, inspect the ball joint seal for
damage. A damaged seal will cause joint failure. If seal damage is found, replace the ball joint.
2/7/2011
Document ID: 360132
Page 1 of 3
Lower Control Arm Ball Joint Replacement

Removal Procedure
Tools Required
J 9519-7 Remover
J 9519-16 Installer
J 9519-17 Spacer Tube
J 9519-18 Screw
J 9519-23 Clamp
Wheels.
2. If Electronic Level Control equipped, remove the height sensor link from the right control
arm.
3. Remove the parking brake cable retaining clip at the left control arm.
4. Using the J 24319-01 , separate the adjustment link from the knuckle (6).
5. Support the control arm (5) with a suitable jack. The control arm must be supported to
prevent the spring from forcing it downward.
6. Remove the cotter pin (2) and the slotted hex nut from the ball joint (4). Turn the nut over
and install with the flat portion facing upward. Do not tighten the nut.
Failure to use the recommended tools may cause damage to the ball joint and seal.
2/7/2011
Document ID: 360132
Page 2 of 3
7. Using the J 34505 , separate the knuckle from the ball stud (3).
8. Remove the slotted hex nut (1).
9. Install the tools on the ball joint and on the control arm.
10. Press the ball joint out of the control arm (1).
1. Install the tools on the ball joint and on the control arm.
2. Press the new ball joint into the control arm.
2/7/2011
Document ID: 360132
Page 3 of 3
3. Install the knuckle (6) on the ball joint stud (3) using the new slotted hex nut (1).
Tighten
1. Tighten the nut to 10 Nm (88 lb in).
2. Tighten the nut an additional four flats. The torque should be 55 Nm (40 lb ft)
minimum.
3. Tighten the nut up to one more flat to align the slot with the cotter pin hole.
4. Install the cotter pin (2).
5. Install the adjustment link to the knuckle. Position the boot toward the front of the vehicle.
Tighten
Tighten the slotted hex nut to 45 Nm (33 lb in).
Important: After tightening the slotted hex nut to specification, align the slot in the nut to
cotter pin hole by tightening only. Do not loosen the nut to install the cotter pin.
6.
7.
8.
9.
Lubricate the ball joint and the adjustment link.

If ELC-equipped, install the height sensor link to the right control arms.
Install the parking brake cable retaining clip at the left control arm.
Install the wheel and the tire.
Tighten
2/7/2011
Document ID: 360134
Page 1 of 3
Rear Axle Lower Control Arm Replacement

Removal Procedure
Tools Required
J 23028-A Rear Coil Spring Remover and Installer
1. Remove the adjustment link retaining nut (1) and the link from the control arm (6).
2. Remove the spring. Refer to Coil Spring Replacement .
3. Remove the cotter pin (5) and the slotted hex nut (4) from the ball joint. Turn the nut over
and install the nut with the flat portion facing upward. Do not tighten the nut.
Failure to use the recommended tools may cause damage to the ball joint and seal.
4. Using the J 34505 , separate the knuckle (3) from the ball stud. Remove the slotted hex nut
(4).
5. Remove the control arm (6).
2/7/2011
Document ID: 360134
Page 2 of 3
1. Position the control arm ball joint stud (6) in the knuckle boss (3).
2. Install a new slotted hex nut (4).
Tighten
1. Tighten the nut to 10 Nm (88 lb in).
2. Tighten the nut an additional four flats; torque should be 55 Nm (40 lb ft) minimum. It
may be necessary to partially load the joint to keep the ball stud from rotating while
the nut is being tightened.
3. Tighten the nut up to one more flat to align the slot with the cotter pin hole.
3. Install the cotter pin (5).
4. Install the spring. Refer to Coil Spring Replacement .
5. Connect the adjustment link to the control arm (6) with the retaining nut (1).
Tighten
Tighten the link retaining nut to 85 Nm (63 lb ft).
Important: The control arm nuts (1) should be tightened with the vehicle unsupported and
resting on its wheels at the normal trim height. Failure to follow this procedure may
adversely affect the ride and handling of the vehicle.
Tighten
Tighten the control arm nuts (1) to 115 Nm (85 lb ft). Optional torque: Tighten the
control arm bolts (2) to 182 Nm (134 lb ft).
Tighten the stabilizer shaft link bolt to 17 Nm (13 lb ft).
2/7/2011
Document ID: 360134
Page 3 of 3
6. Lubricate the ball joint and the adjustment link.
2/7/2011
Document ID: 360142
Page 1 of 2
Tie Rod Replacement

Removal Procedure
Tools Required
J 24319-01 Universal Steering Linkage Puller.
1. Remove the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
2.
3.
4.
5.
Remove the cotter pin and the slotted hex nut.

Remove the brake line.
Remove the wheel speed sensor harness and bracket in order to install linkage puller.
Use J 24319-01 to separate the adjustment link (9) from the knuckle.
Notice: When separating a linkage joint, do not try to disengage the joint by driving a wedge
between the joint and the attached part. Seal damage may result.
6. Remove the link retaining nut and the link from the control arm.
1. Install the brake line.
2. Install the wheel speed sensor harness and bracket.
2/7/2011
Document ID: 360142
Page 2 of 2
3. Install the link (9) to the control arm with the retaining nut.
4. Install the link to the knuckle. Position the boot toward the front of the vehicle
Tighten
Tighten the retaining nut to 85 Nm (63 lb ft).
Tighten the slotted hex nut to 45 Nm (33 lb ft).
Important: After tightening the slotted hex nut to specification, align the slot in the
nut to the cotter pin hole by tightening only. Do not loosen the nut to install the cotter
pin.
5. Install the cotter pin.
6. Lubricate the adjustment link joint.
Tighten
Check and set the rear wheel alignment after installing the adjustment link. Refer to Wheel
Alignment Specifications in Wheel Alignment.
2/7/2011
Document ID: 360145
Page 1 of 2
Stabilizer Shaft Replacement

Removal Procedure
1. Remove the rear wheels and the tires.
2. Remove the stabilizer shaft link assembly bolt (7) and the nut (4). Remove the retainer (5)
and the insulators (6) from the stabilizer shaft bracket (8).
3. Remove the link bolt (10), and bend the open end of the link (9) downward.
4. Remove the stabilizer shaft (11) and the insulators (6).
2/7/2011
Document ID: 360145
Page 2 of 2
1. Install the stabilizer shaft (11) and the insulators (6). Install the insulator (6) into the link (9)
with the slit rearward.
2. Bend the link upward to close around the insulator, and install the link bolt (10).
3. Install the link assembly insulators(6), the retainers(5), the support bolt (7) and the nut (4).
Tighten
Tighten the link assembly nut to 17 Nm (13 lb ft).
Tighten the link bolt to 23 Nm (17 lb ft).
4. Install the wheels and the tires.
Tighten
2/7/2011
Document ID: 360148
Page 1 of 2
Stabilizer Shaft Insulator Replacement

Removal Procedure
1. Remove the rear wheels and the tires.
2. Bend the link bolt, and bend the open end of the link (10) downward.
3. Remove the stabilizer shaft insulators (6).
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Document ID: 360148
Page 2 of 2
1. Install the stabilizer shaft and the insulators (6). Install the insulator into the link with the slit
rearward.
2. Bend the link (9) upward to close around the insulator, and install the link bolt (10).
3. Install the link assembly insulators, the retainers, the support bolt and nut.
Tighten
Tighten the link assembly nut to 17 Nm (13 lb ft).
Tighten the link bolt to 23 Nm (17 lb ft).
4. Install the wheels and the tires.
Tighten
2/7/2011
Document ID: 360152
Page 1 of 4
Coil Spring Replacement

Removal Procedure
Tools Required
J 23028-A Rear Coil Spring Remover and Installer
Important: Support the vehicle so that the control arm hangs free. Refer to Lifting and Jacking
the Vehicle in General Information.
1. Remove the rear wheel and the tire.
2. If Electronic Level Control (ELC) -equipped, remove the height sensor link from the right
control arm.
3. Remove the parking brake cable retaining clip from the left control arm.
4. Remove the rear stabilizer shaft from the bracket on the knuckle.
5. Mount the J 23028-A on the transmission jack (2) and position to cradle the control arm
bushings.
Caution: Tool J 23028-01 should be secured to a suitable jack or personal injury could
result.
Important: Place a chain around the spring and through the control arm pivot bolts.
6. Raise the jack to remove the tension from the control arm pivot bolts.
2/7/2011
Document ID: 360152
Page 2 of 4
7. Remove the rear bolt and the nut from the rear control arm.
8. Slowly maneuver the jack to relieve the tension from the front control arm bolt.
9. Remove the front bolt and nut from the rear control arm.
Important: Do not apply force to the control arm and/or ball joint to remove the spring.
Proper maneuvering of the spring will allow for easy removal.
10. Lower the jack to pivot the control arm downward. When all the compression is removed
from the spring, remove the safety change, the spring, and the insulators.
11. Inspect the insulators carefully and replace if cut or torn. Replace the insulators if the vehicle
has over 80,450 km (50,000 miles).
2/7/2011
Document ID: 360152
Page 3 of 4
1. Snap the upper insulator onto the spring before installation.

Important: Install the coil springs so the upper ends are positioned as shown in the above
figure.
2. Position the lower insulator and the spring in the vehicle.
3. Using the J 23028-A mounted on the transmission jack (2), raise the control arm into
position.
4. Slowly maneuver the jack to permit the installation of the control arm bolts and the nuts.
5. Install the rear stabilizer shaft to the knuckle bracket with the link assembly.
6. If ELC-equipped, install the height sensor link from the right control arm.
2/7/2011
Document ID: 360152
Page 4 of 4
7. Install the parking brake cable retaining clip at the left control arm.
Important: The control arm nuts should be tightened with the vehicle unsupported and
resting on its wheels at the normal trim height. Failure to do so may adversely affect ride and
handling.
8. Install the rear wheel and the tire.
Tighten
Tighten wheel nuts to 140 Nm (100 lb ft).
Tighten the control arm nuts to 115 Nm (85 lb ft). Optional Torque: Tighten the
control arm bolts to 182 Nm (134 lb ft).
Tighten the stabilizer shaft link bolts to 17 Nm (13 lb ft).
2/7/2011
Document ID: 360191
Page 1 of 3
Outer Adjustment Link Replacement

Removal Procedure
Tools Required
1. Remove the wheel and tire.

2. Remove the cotter pin (2) and slotted hex nut (1).
2/7/2011
Document ID: 360191
Page 2 of 3
3. Using J 24319-B, separate the adjustment link from the knuckle.

4. Loosen the adjustment link retaining nut.
5. Remove the adjustment link.
1. Install the adjustment link with retaining nut.
Tighten
Tighten the retaining nut to 85 Nm (63 lb ft).
2. Install the link to the knuckle and position the boot toward the front of the vehicle.
3. Install the slotted hex nut.
Tighten
4. After tightening the slotted hex nut to specification, align the slot in the nut to cotter pin hole
by tightening only, do not loosen the nut to align for the cotter pin (2).
2/7/2011
Document ID: 360191
Page 3 of 3
Tighten
2/7/2011
Document ID: 360195
Page 1 of 2
Strut Assembly Replacement

Removal Procedure
Caution: Floor jack must remain under the lower control arm during removal and installation
to retain the lower control arm in position. Failure to do so could result in personal injury.
1.
2.
3.
4.
5.
6.
7.
8.
Remove the rear seat cushion and seatback to gain access to the strut tower mounting nuts.
Remove the wheel and tire.
If ELC equipped, remove the air tube from the strut.
Support the control arm with a suitable jack stand.
Remove the strut to knuckle nuts and bolts.
Remove the upper nuts from the strut.
Remove the strut from the knuckle.
Remove the strut.
2/7/2011
Document ID: 360195
Page 2 of 2
1. Install the strut.

2. Install the strut to tower nuts.
Tighten
3. Install the strut to knuckle bolts and nuts.
Tighten
Tighten the strut to knuckle bolts to 190 Nm (140 lb ft).
4. Connect the air tube to the strut.
5. Install the rear seatback and seat cushion. Refer to Seatback and Seat Cushion in Seats.
Tighten
7. Check and reset alignment. Refer to Wheel Alignment Specifications .
2/7/2011
Document ID: 360200
Page 1 of 2
Wheel Stud Replacement

Removal Procedure

2. Remove the brake drum. Refer to Brake Drum Replacement in Brakes .
3. Remove the wheel stud using the J 6627-A .
2/7/2011
Document ID: 360200
1.
2.
3.
4.
5.
Page 2 of 2
Install the new stud from the back side of the hub.
Install the four flat washers on the stud.
Install the wheel nut (2) with the flat side toward washers.
Tighten the nut until the stud head is properly seated in the hub flange.
Install the brake drum. Brake Drum Replacement in Brakes.

Tighten
2/7/2011
Document ID: 104873
Page 1 of 4
| Achieva, Grand Am, Skylark (VIN N) Service Manual | Transmission/Transaxle |

Automatic Transaxle - 4T60-E | Repair Instructions | Document ID: 104873
1996 Buick Skylark
Range Selector Lever Cable Replacement

Removal Procedure
in General Information.
2. Remove the automatic transmission range select lever cable from the selector lever.
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3. Remove the range select lever cable from the cable bracket.
4. Remove the center console.
5. Remove the range select lever cable from the automatic transmission control.
6. Remove the cable grommet at the cowl.
7. Remove the cable from the vehicle.
1. Install the cable to the vehicle through the cowl and the carpet.
2. Install the cable grommet in the cowl.
3. Install the cable grommet bolts in the cowl.
Tighten
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Document ID: 104873
Page 3 of 4

4. Install the range select lever cable at the automatic transmission control.
5. Install the center console.
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Document ID: 104873
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6. Install the range select lever cable to the cable bracket.
7. Install the range select lever cable to the selector lever.

9. Adjust the cable.
9.1. Place the shift lever in N (Neutral). Rotate the selector shaft clockwise from P (Park)
through R (Reverse) into N (Neutral).
9.2. Place the shift control assembly in N (Neutral).
9.3. Push the tab on the cable adjuster in order to adjust the cable in the cable mounting
bracket.
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Document ID: 97776
Page 1 of 4

1996 Buick Skylark
Park Lock Cable Replacement (Oldsmobile)

Removal Procedure
2.
3.
4.
5.
Remove the console as necessary.

Place the shift lever in (P) Park.
Turn the ignition key to the RUN position.
Remove the left sound insulator and the knee bolster as necessary.
Important: Do not attempt to perform the following steps with the key in any other position.
6.
7.
8.
9.
Slip a screwdriver blade into the slot provided in the ignition switch inhibitor.
Depress the cable latch.
Pull the cable from the inhibitor.
Pull the cable adjuster locking button at the shift control bracket to the UP position.
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10/14/2010
Document ID: 97776
Page 2 of 4
10. Pull rearward on the cable end in order to unsnap the cable from the park lock lever pin on
the shift control assembly.
11. Depress the two cable adjuster tangs and remove from the shifter control assembly.
12. Remove the cable clips.
1. With the cable adjuster locking button in the UP position and the shift lever in the (P) Park
position, snap the cable connector into the shifter control bracket. Ensure that the two cable
adjuster tangs are fully engaged.
2. With the ignition in the RUN position, snap the cable into the inhibitor housing.
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10/14/2010
Document ID: 97776
Page 3 of 4
Important: Do not insert the cable with the key in any other position except RUN.
3.
4.
5.
6.
Turn the ignition key to LOCK.

Snap the cable end onto the park lock lever pin on the shift control assembly.
Complete the following steps in order to adjust the assembly:
Ensure that the ignition key is in the LOCK position. If the key can not be rotated to the
LOCK position, lift the adjuster locking button and slide the adjuster rearward in the car
compressing the spring and hold. Rotate the key in order to lock.
7. Ensure that the cable adjuster locking button is in the UP position.

8. Grasp the park lock cable near the forward end of the adjuster spring. Push the cable toward
the front of the vehicle in order to remove the slack and release.
9. Move the cable adjuster rearward in the vehicle 1.5 mm (1/16 in) from the position
established in the previous step.
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10. While holding this position, push the adjuster locking button down flush with the adjuster
10/14/2010
Document ID: 97776
11.
12.
13.
14.
Page 4 of 4
body.
Install the left sound insulator and the knee bolster.
Install the console.
In order to verify correct functional operation of the park lock system, perform the following
steps:
14.1. Turn the ignition key to the OFF/LOCK position.
14.2. If you can shift out of (P) Park, readjust the park lock cable.
14.3. Turn the ignition key to the RUN position.
14.4. Shift to (N) Neutral.
14.5. If you can turn the ignition key to the OFF/LOCK position and are able to remove the
key, readjust the park lock cable.
14.6. Return the shifter to (P) Park.
14.7. Turn the ignition key to OFF/LOCK.
14.8. If you can not remove the key, readjust the park lock cable.
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10/14/2010
Document ID: 104686
Page 1 of 4

1996 Buick Skylark
Transmission Control Replacement

Removal Procedure
2. Remove the automatic transmission control lever handle.

3. Remove the console.
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Document ID: 104686
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4. Remove the range select lever cable from the automatic transmission control.
5. Remove the electrical connector.
6. Remove the automatic transmission control bolts.

7. Remove the automatic transmission control.
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Document ID: 104686
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1. Install the automatic transmission control.

2. Install the automatic transmission control bolts.
3. Install the electrical connector.
4. Install the range select lever cable to the automatic transmission control.
5. Install the console. Refer to Console in Instrument Panel, Gauges and Console.
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Document ID: 104686
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6. Install the automatic transmission control lever handle.

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Document ID: 105984
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1996 Buick Skylark
Park/Neutral Position Switch Replacement

Removal Procedure
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Document ID: 105984
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3. Remove the shift linkage retaining nut.
4. Remove the shift linkage.
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Document ID: 105984
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5. Remove the lever.
6. Remove the park/neutral position switch mounting bolts.

7. Remove the park/neutral position switch assembly.
Using Old Switch
1.
2.
3.
4.
Place the shift shaft in N (Neutral).

Align the flats of the shift shaft with the switch.
Loosely install the park/neutral position switch mounting bolts.
Insert the gauge pin in the service adjustment hole. Rotate the switch until the pin drops in
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to a depth of 9 mm (9/64 in).
Document ID: 105984
Page 4 of 6
Tighten
Important: Ensure that the engine will only start in the P (Park) or the N (Neutral) position.
Readjust the switch if the engine will start in any other position.
5. Remove the gauge pin.
Using New Switch

1. Place the shift shaft in the N (Neutral) position.
2. Align the flats of the shift shaft to the flats in the switch.
3. Install the park/neutral position switch assembly.

4. Install the park/neutral position switch mounting bolts.
Tighten
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Document ID: 105984
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5. Install the lever.
6. Install the shift linkage.
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Document ID: 105984
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7. Install the shift linkage retaining nut.

8. Align the holes with the mounting boss on the transmission. Place the shift control lever in
the N (Neutral) position. Do not rotate the switch. The switch is pinned in the N (Neutral)
position. If the switch has been rotated and the pin is broken, adjust the switch. Refer to the
using old switch installation procedures.
9. If the switch has been rotated and the pin is broken, adjust the switch by using the Old
Switch procedure.
Important: Ensure that the engine will only start in P (Park) or N (Neutral). Readjust the
switch if the engine will start in any other position. Refer to the old switch installation
procedures.
10.
11.
12.
13.

Place the transmission control shifter assembly in the N (Neutral) notch in the detent plate.
Loosen the park/neutral position switch attaching bolts.
Rotate the switch on the shifter assembly in order to align the service adjustment hole with
the carrier tang hole.
14. Insert a 2.34 mm (3/32 in) maximum diameter gauge pin to a depth of 9.0 mm (9/64 in).
Tighten
15. Remove the gauge pin.
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Document ID: 104690
Page 1 of 6

1996 Buick Skylark
Automatic Transmission Fluid and Filter Replacement

Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to General Vehicle Lifting and Jacking in General
Information.
2. Place a drain pan under the transmission oil pan.
3. Remove the oil pan bolts from the front and the sides only.
4. Loosen the rear oil pan bolts approximately 4 turns.
Notice: Pry the oil pan down carefully in order to prevent damage to the transmission case
or the oil pan sealing surfaces.
5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the oil to drain.
6. Inspect the oil color. Refer to Transmission Fluid Checking Procedure .
7. Remove the remaining oil pan bolts.
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Document ID: 104690
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8. Remove the oil pan.
9. Remove the oil pan gasket.
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Document ID: 104690
10.
11.
12.
13.
Page 3 of 6
Remove the oil filter.

Remove the oil filter O-ring seal.
Inspect the O-ring seal. The O-ring seal may be stuck in the case.
Remove all traces of old gasket material. Clean the transmission case and the oil pan gasket
surfaces with solvent, and allow to air dry.
Tools Required
J 36850 Transjel Transmission Assembly Lubricant
Notice: Use J 36850 or equivalent during assembly in order to retain checkballs or to
lubricate components. Lubricants other than the recommended assembly lube changes the
transmission fluid characteristics and causes undesirable shift conditions or filter clogging.
1. Coat the seal with a small amount of J 36850 , or equivalent.
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Document ID: 104690
Page 4 of 6
2. Install a new seal into the case.

3. Install a new filter into the case.
4. Install a new oil pan gasket.
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Document ID: 104690
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5. Install the oil pan.
6. Install the oil pan bolts.

Tighten
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Document ID: 104690
7.
8.
9.
10.
11.
12.
Page 6 of 6
Inspect the oil pan bolts and the washers.

Use adhesive and sealant compound GM P/N 12345382, or equivalent.
Lower the vehicle.
Fill the transmission to the proper level with DEXRON--III oil.
Adjust the cold oil level reading for the initial fill. Do not overfill.
Inspect the oil pan gasket for leaks.
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Document ID: 97785
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1996 Buick Skylark
Oil Pan Replacement

Removal Procedure
Information.
2. Loosen the oil pan bolts.
3. Drain the oil.
4. Remove the oil pan attaching bolts.
5. Remove the oil pan.

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Document ID: 97785
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6. Remove the oil pan gasket.
1. Install the oil pan gasket. If the sealing ribs are damaged, use a new gasket.
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Document ID: 97785
Page 3 of 4
2. Install the oil pan.
3. Install the oil pan attaching bolts.

Tighten
Tighten the oil pan bolts to 14 Nm (124 lb in).
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10/14/2010
Document ID: 97785
Page 4 of 4

5. Refill the transmission to the proper level with DEXRON III oil.
6. Inspect the oil pan gasket for leaks.
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10/14/2010
Document ID: 97235
Page 1 of 2

1996 Buick Skylark
Automatic Transmission Fluid Filter and Seal

Replacement
Removal Procedure
Tools Required
J 6125-1B Slide Hammer
J 23129 Axle Boot Remover
Information.
2. Drain the oil.
3. Remove the oil pan attaching bolts, oil pan, and the gasket. Refer to Oil Pan Replacement .
4. Remove the oil filter. Use a long screwdriver in order to pry the filter neck out of the seal.
5. Remove the seal. Use the J 6125-1B and the J 23129 .
6. Check the oil filter seal for damage or wear.
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10/14/2010
Document ID: 97235
1.
2.
3.
4.
5.
Page 2 of 2
Install the new oil filter and the seal.

Install the oil pan gasket, oil pan and the attaching bolts. Refer to Oil Pan Replacement .
Lower the vehicle.
Fill the transmission to the proper level with DEXRON III oil.
Inspect the oil pan gasket for leaks.
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10/14/2010
Document ID: 105813
Page 1 of 4

1996 Buick Skylark
Filler Tube Replacement

Removal Procedure
1. Remove the bolt from the tube to transmission case.

Information.
3. Place a drain pan under the transmission.
4. Remove the filler tube.

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Document ID: 105813
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5. Remove the seal from the transmission.
1. Install the new seal into the transmission.
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Document ID: 105813
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2. Install the tube into the transmission. Do not damage the seal.
4. Install the bolt through the tube bracket into the transmission case.
Tighten
Tighten the bolts to 9 to 13 Nm (80 to 115 lb in).
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Document ID: 105813
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Document ID: 97274
Page 1 of 4

1996 Buick Skylark
Vehicle Speed Sensor Replacement

Removal Procedure
Information.
2. Disconnect the speed sensor electrical connector.
3. Remove the speed sensor bolt.
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Document ID: 97274
Page 2 of 4
4. Remove the vehicle speed sensor from the case extension.

5. Remove the O-ring from vehicle speed sensor.
1. Install the O-ring onto the vehicle speed sensor.

2. Install the vehicle speed sensor into the case extension.
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Document ID: 97274
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3. Install the speed sensor bolt.

Tighten
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Document ID: 97274
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10/14/2010
Document ID: 97276
Page 1 of 3

1996 Buick Skylark
Accumulator and 2-1 Manual Servo Replacement

Removal Procedure
Tools Required
J 23129 Axle Boot Remover
Information.
2. Drain the oil.
3. Remove the oil pan bolts, the oil pan and the gasket. Refer to Oil Pan Replacement .
4. Remove the oil filter. Refer to Oil Filter and Seal Replacement .
5. Check the oil filter seal for damage or wear.
6. Remove the oil seal. Use the J 6125-1B and the J 23129 , if needed.
7. Remove the attaching bolts.

8. Remove the accumulator assembly.
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Document ID: 97276
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9. Remove the 2-1 manual servo piston assembly and the filter.
10. Remove the seal.
11. To disassemble and inspect the accumulator and 2-1 manual servo assemblies, refer to the
unit repair manual.
Important: Ensure that the seal is installed in the correct location. If the seal is not installed
or is installed in the wrong location, the transmission will operate only in R (Reverse).
1. Install the 2-1 manual piston assembly, filter and seal.
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2. Install the accumulator assembly.

3. Install the attaching bolts.
Tighten
Tighten the accumulator assembly bolts to 27 Nm 20 lb ft).
4. Install the oil filter. Refer to Oil Filter and Seal Replacement .
5. Install the oil pan, the oil pan bolts and the gasket. Do not reuse the gasket if the sealing ribs
are damaged. Refer to Oil Pan Replacement .
7. Fill the transmission oil to the proper level.
8. Inspect the oil pan gasket for leaks.
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10/14/2010
Document ID: 99289
Page 1 of 2

1996 Buick Skylark
Scavenger Oil Scoop Replacement

Removal Procedure
1. Raise the vehicle. Refer to General Vehicle Lifting and Jacking in General Information.
2. Support the vehicle on a suitable stand.
3. Remove the pan. Refer to Oil Pan Replacement .
4. Remove the oil scoop retaining bolt.

5. Remove the oil scoop.
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Document ID: 99289
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1. Install the oil scoop.

2. Install the retaining bolt.
Tighten
Refer to
3. Install the pan. Refer to Oil Pan Replacement .
5. Adjust the fluid level.
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10/14/2010
Document ID: 106005
Page 1 of 3

1996 Buick Skylark
Reverse Servo Replacement (2.2L and 2.4L Engines)

Removal Procedure
2. Raise the vehicle and suitably support the vehicle. Refer to General Vehicle Lifting and
Jacking in General Information.
3. Depress the servo cover.

4. Remove the snap ring and the servo cover.
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Document ID: 106005
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5. Remove the following parts:

The piston assembly
The sealing ring
The servo spring
6. For the disassembly of the servo piston assembly, refer to Reverse Servo Disassemble .
1. Install the following parts:

The servo spring
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The sealing ring

The piston assembly
2. Install the servo cover and the snap ring.

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1996 Buick Skylark
Reverse Servo Replacement (L82)

Removal Procedure
Disconnect the negative battery cable. Refer to
Remove the EGR pipe from the exhaust manifold.
Remove the exhaust crossover pipe. Refer to 3100 (VIN M) Exhaust Crossover Pipe in
Exhaust.
Depress the servo cover.
Remove the snap ring and the servo cover.
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Remove the following parts:
The piston assembly

The sealing ring
The servo spring
For the disassembly of the servo piston assembly, refer to Reverse Servo Disassemble .
1. Install the following parts:

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The servo spring

The sealing ring
The piston assembly
2.
3.
4.
5.
Install the servo cover and the snap ring.

Install the exhaust crossover pipe. Refer to 3100 (VIN M) Exhaust Crossover Pipe in Exhaust.
Install the EGR pipe to the exhaust manifold.
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Document ID: 97798
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1996 Buick Skylark
Forward Servo Replacement

Removal Procedure
1. Remove the forward servo attaching bolts.

2. Remove the servo cover.
3. Remove the servo piston assembly.
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4. Remove the following items:

Sealing ring
Servo spring
5. For disassembly of the forward servo piston assembly, refer to Forward Servo Disassemble .
1. Install the following items:

Servo spring
Sealing ring
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2. Install the servo piston assembly.
3. Install the servo cover.

4. Install the forward servo attaching bolts.
5. For disassembly of the servo piston assembly, refer to Transmission Unit Repair Manual.
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Document ID: 105915
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1996 Buick Skylark
Transmission Fluid Cooler Hose Replacement

Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to General Information.
2. Remove the transmission oil cooler lines from the radiator.
3. Remove the transmission oil cooler lines from the transmission.
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1. Install the transmission oil cooler lines to the transmission.

Tighten
Tighten the pipe fitting 32 to 44 Nm (24 to 33 lb ft).
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2. Install the transmission oil cooler lines to the radiator.
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1996 Buick Skylark
Flywheel to Torque Converter Bolt Replacement

Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to General Information.
2. Remove the transmission converter cover bolts.

3. Remove the transmission converter cover.
4. Mark the relationship of the converter to the flywheel.
5. Remove the three bolts that attach the converter to the flywheel.
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1. Install the bolts that attach the converter to the flywheel.

Tighten
Tighten all of the bolts to 62 Nm (46 lb ft). Re-torque the first bolt after all three have been
tightened.
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2. Install the converter cover.

3. Install the converter cover bolts.
Tighten
Tighten the converter cover bolts to 13 Nm (115 lb in).
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1996 Buick Skylark
Control Valve Body Replacement

Removal Procedure
2. Remove the case side cover. Refer to Case Side Cover Replacement (W/ Gasket) .
3. Remove the wiring harness as necessary.

4. Remove the oil pump. Refer to Oil Pump Replacement
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5. Remove the valve body to channel plate bolts.
6. Remove the valve body. Leave the spacer plate with the transmission.
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7. Remove the spacer plate and the spacer plate gasket, as necessary.
8. Remove the solenoid screens.
Notice: The assembly of some components will require the use of an assembly lube. Always
use J 36850 Transjel or petroleum jelly during assembly. Greases other than the
recommended assembly lube will change the transmission fluid characteristics and cause
undesirable shift conditions and/or filter clogging.
1. In order to retain the checkballs in their proper locations, use the J 36850 or equivalent
petroleum jelly.
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2. Install the solenoid screens, if necessary.

3. Install the spacer plate and the spacer plate gasket, as necessary.
4. Install the valve body and the valve body gasket.
5. Install the valve body to channel plate bolts to specifications.

Notice: Use a torque wrench to tighten the pump to valve body bolts. Do not exceed the
torque specifications.
Notice: Install all the valve body bolts, then torque the bolts in a spiral pattern starting from
the center, as shown. If you torque the bolts at random, you may distort the valve bores.
This will inhibit valve operation.
Important: Do not use impact type tools on the valve body or the pump assembly.
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6. Install the oil pump. Refer to Oil Pump Replacement .
7.
8.
9.
10.
Install the wiring harness.

Install the case side cover. Refer to Case Side Cover Replacement (W/ Gasket) .
Adjust the oil level.
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Document ID: 97292
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1996 Buick Skylark
Oil Pump Replacement

Removal Procedure
Information.
4. Remove the wiring harness as necessary.
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Document ID: 97292
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5. Remove the oil pump to valve body bolts.

6. Inspect the oil pump. Refer to Oil Pump Disassemble .
1. Install the oil pump to the valve body.
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Document ID: 97292
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Notice: Use a torque wrench to tighten the pump to valve body bolts. Do not exceed the
torque specifications.
2. Install the oil pump to valve body bolts.
3.
4.
5.
6.
Install the wiring harness, if removed.

Install the case side cover. Refer to Case Side Cover Replacement (W/ Gasket) .
Lower the vehicle.
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1996 Buick Skylark
Control Valve Body Cover Replacement (W/ Gasket)

Removal Procedure
2. Remove the park/neutral position switch. Refer to Park/Neutral Position Switch Replacement .
Information.
4. Remove the left front tire and wheel assembly. Refer to Wheel Removal in Tires and Wheels.
5. Remove the inner splash shield.
6. Remove the tie rod end from the knuckle assembly. Refer to Stabilizer Shaft and Link in
Front Suspension.
7. Remove the stabilizer shaft link from the lower control arm. Refer to Stabilizer Shaft and Link
in Front Suspension.
8. Remove the ball joint from the steering knuckle. Refer to Ball Joint in Front Suspension.
9. Remove the drive axle from the transmission. Refer to Drive Axle in Drive Axle On-Vehicle
Service.
10. Remove the pinch bolt from the steering gear intermediate shaft.
Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear
stub shaft can result in damage to the steering gear or to the intermediate shaft. This
damage may cause loss of steering control, which could result in an accident and possible
personal injury.
11. Remove the intermediate shaft from the steering gear.
12. Position a transmission jack under the transmission oil pan. Raise the jack until the jack
supports the transmission.
13. Remove the three frame-to-body bolts on the left side.
14. Lower the transmission jack and the transmission in order to gain access to the case side
cover.
15. Remove the oil cooler pipes at the case. Refer to Automatic Transmission Oil Cooler Pipes
Replacement .
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16. Remove the case side cover bolts.
17. Remove the case side cover.

18. Clean the case and side cover gasket surfaces.
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1. Install the new gaskets on the case.

2. Install the case side cover.
3. Install the new side cover bolts.

Tighten
Tighten the side cover bolts to 11 Nm (98 lb in).
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4. Install the oil cooler pipes to the transmission. Refer to Automatic Transmission Oil Cooler
Pipes Replacement .
5. Raise the transmission so that the frame bolts can be installed.
6. Install the three frame-to-body bolts.
Tighten
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Remove the transmission jack.

Install the intermediate shaft to the steering gear.
Install the pinch bolt at the intermediate shaft.
Install the drive axle to the transmission. Refer to Drive Axle in Drive Axle On-Vehicle
Service.
Install the ball joint to the steering knuckle. Refer to Ball Joint in Front Suspension.
Remove the drive axle seal protectors.
Install the stabilizer shaft link to the lower control arm. Refer to Stabilizer Shaft and Link in
Front Suspension.
Install the tie rod end to the knuckle. Refer to Stabilizer Shaft and Link in Front Suspension.
Install the inner splash shield.
Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
Lower the vehicle.
Install the park/neutral position switch. Refer to Park/Neutral Position Switch Replacement .
Inspect for leaks.
Check the fluid level.
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Document ID: 97807
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1996 Buick Skylark
Vacuum Modulator Replacement

Removal Procedure
1. Remove the vacuum line at the modulator.
2. Remove the modulator bolt and the retainer.
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3. Remove the vacuum modulator and the O-ring.
1. Install the modulator and a new O-ring.
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2. Install the modulator retainer and the bolt.

Tighten
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3. Install the vacuum line at the modulator.
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Page 1 of 7

1996 Buick Skylark
Case Extension Replacement (W/ Final Drive)

Removal Procedure
Tools Required
J 34757 Output Shaft C-Ring Remover and Installer
2. Raise the vehicle. Support the vehicle. Refer to Vehicle Lifting and Jacking in General
Information.
3. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
4. Remove the right front tire and the wheel assembly. Refer to Wheel Removal in Suspension.
Important: Carefully guide the right drive axle output shaft past the lip seal. Do not allow
the shaft splines to contact any portion of the lip seal surface; otherwise, damage to the seal
will occur.
5.
6.
7.
8.
9.
Remove the right drive axle from the transmission. Refer to Drive Axle in Driveline/Axle.
Remove the torque strut bracket from the transmission.
Loosen the torque strut to bracket bolt as needed.
Swing the bracket out of the way.
Remove the transmission brace from the engine bracket.
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10. Remove the case extension bolts.
11. Remove the case extension assembly and the seal.
12. Remove the thrust bearing and the thrust bearing washer.
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13. Rotate the final drive assembly until the opening in the snap ring is visible. Use the J 34757
to push the snap ring partially off the output shaft.
14. Remove the final drive sun gear.

15. Remove the parking gear.
16. Remove the thrust bearing.
Important: Refer to Transmission Unit Repair Manual if further service is needed on the final
drive assembly.
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17. Remove the final drive sun gear shaft.
Tools Required
J 36850 Transjel
J 34757 Output Shaft C-Ring Remover and Installer
J 37292-B Axle Seal Protector
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Document ID: 97808
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1. Install the final drive sun gear shaft.
2. Install the thrust bearing.

3. Install the parking gear.
4. Install the final drive sun gear.
5. Install the final drive assembly onto the output shaft. Use the J 34757 in order to install the
snap ring onto the output shaft.
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6. Install the washer and the thrust bearing onto the final drive assembly. Use the J 36850 or
the equivalent (petroleum jelly), in order to retain the washer and the bearing.
7. Install the seal and the case extension.
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8. Install the case extension bolts.

Tighten
9. Install the transmission brace to the engine bracket.
10. Install the torque strut bracket to the transmission.
Important: Before installing the right side drive axle, install the J 37292-B . Install the tool
in a position so that it can be pulled out after the drive axle is installed (T-handle between 5
and 7 o'clock).
11. Install the right drive axle to the transmission. Refer to Drive Axle in Driveline/Axle.
12. Install the right front tire and wheel assembly. Refer to Wheel Installation in Suspension.
13. Remove the J 37292-B . Pull in line with the handle. Ensure that the tool is completely
removed, and no pieces remain inside the transmission.
14. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
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Document ID: 97810
Page 1 of 1

1996 Buick Skylark
Thermo Element Replacement

Removal Procedure
Information.
3. Remove the oil and the oil filter. Refer to Oil Filter and Seal Replacement .
4. Disassemble the following parts:
The washers
The pins
The thermo element
The plate
Tools Required
J 34094-A Thermo Element Height Gauge
1. Set the middle thermo pin height with the J 34094-A .
2. Install the element plate.
3. Install the pin and the washer assemblies. Use the J 34094-A in order to set the height of
both washers. Complete the following steps:
3.1. Set the pin that is furthest from the accumulators.
3.2. Set the other pin. This will ensure that both pins are set correctly.
4. Install the thermo element between the two pins without bending the element too much.
The V in the Thermo element must contact the element plate.
5. Install the oil filter, the oil pan and the gasket. Refer to Oil Pan Replacement and Oil Filter
and Seal Replacement .
7. Adjust the oil level.
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Document ID: 97321
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1996 Buick Skylark
Solenoids and Wiring Harness Replacement

Removal Procedure
Information.
4. Remove the 1-2 shift solenoid retainer.
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5. Remove the 1-2 shift solenoid.
6. Remove the PWM solenoid retainer.
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7. Remove the PWM solenoid.
8. Remove the TCC solenoid retainer.
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Document ID: 97321
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9. Remove the TCC solenoid.
10. Remove the 3-4 shift solenoid retainer.
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11. Remove the 3-4 shift solenoid.
1. Install the 3-4 shift solenoid.
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2. Install the 3-4 shift solenoid retainer.
3. Install the TCC solenoid.
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4. Install the TCC solenoid retainer.
5. Install the PWM solenoid.
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6. Install the PWM solenoid retainer.
7. Install the 1-2 shift solenoid.
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8. Install the 1-2 shift solenoid retainer.

9. Install the case side cover, new gaskets and attaching bolts. Refer to Case Side Cover
Replacement (W/ Gasket) .
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Document ID: 101602
Page 1 of 2

1996 Buick Skylark
Drive Axle Oil Seal Replacement

Removal Procedure
Information.
2. Remove the drive axle. Refer to Drive Axle On-Vehicle Service.
3. Pry out the seal with a screwdriver or other suitable tool. Do not damage the seal bore.
Tools Required
J 34115 Drive Boot Installer
J 37292-B Tear-Away Axle Seal Protector
1. Lubricate the seal lip with a light wipe of transmission fluid.
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2. Install a new seal, using the J 34115 .

3. For the right side axle seal, install the J 37292-B . Install the J 37292-B in a position so that
the tool can be pulled out after drive axle installation (T-handle between the 5 and 7 o'clock
position).
Important: Carefully guide the axle shaft past the lip seal. In order to avoid damage to the
seal, do not let shaft splines contact any part of the lip-seal surface.
4. Install the drive axle. Refer to Drive Axle in Drive Axle On-Vehicle Service.
5. On the right side, remove the J 37292-B by pulling in line with the handle. Make sure that
the J 37292-B is removed completely and that no pieces remain inside the transmission.
6. Inspect for leaks.
7. Inspect the fluid level.
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1996 Buick Skylark
Transmission Mount Replacement

Removal Procedure
Tools Required
J 28467-360
2. Install the J 28467-360 to the transmission.
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3. Remove the upper transmission mount assembly bolts.

Information.
5. Remove the left front tire and the wheel assembly. Refer to Wheel Removal in Tires and
Wheels.
6. Remove the left front splash shield.
7. Remove the transmission mount expansion pipe bolt.
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8. Remove the lower transmission mount assembly bolts.
9. Remove the transmission mount.
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1. Install the transmission mount.
2. Install the lower transmission mount bolts.

Tighten
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3. Install the transmission mount expansion plug.

4. Install the left front splash shield.
5. Install the left front tire and the wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
7. Install the upper transmission mount bolts.

Tighten
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8. Remove the engine support fixture.

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1996 Buick Skylark
Transmission Replacement (3100 VIN M)

Removal Procedure
J 28467-360 Engine Support Fixture
J 35944 Oil Cooler Flushing Tool
2. Remove the air intake duct. Refer to Engine Controls.
3. Remove the shift linkage from the transmission.
4. Remove the vacuum modulator vacuum line at the modulator.
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Important: When servicing requires that the T latch type wiring connector be disconnected
from the switch, care must be taken in order to ensure proper reassembly of both the
connector and the T latch. Failure to do so may result in intermittent loss of switch functions.
5. Remove the following wiring connectors:
The TCC connector
The Park/Neutral position switch
The shift solenoid connector
6. Install the J 28467-360 .
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7. Remove the top two transmission to engine bolts.

8. Remove the rubber hose from the transmission to vent pipe.
9. Remove the remaining upper engine to transmission bolts.

Information.
11. Remove both the tire and the wire assemblies. Refer to Wheel Removal in Tires and Wheels.
12. Remove the right and the left splash shields.
13. Remove both the front ABS wheel speed sensors and the harness from the left side
suspension support. Refer to Front Wheel Speed Sensor in Antilock Brake System and
Enhanced Traction System.
14. Remove both of the ball joints from the control arms. Refer to Ball Joint in Front Suspension.
15. Remove the left stabilizer shaft link pin bolt. Refer to Stabilizer Link in Front Suspension.
16. Remove the left stabilizer shaft frame bushing clamp nuts. Refer to Stabilizer Shaft in Front
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Suspension.
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17. Remove the left suspension support assembly. Refer to Control Arm and/or Suspension
Support in Front Suspension.
18. Remove both of the drive axles. Refer to Drive Axle in Drive Axle On-Vehicle Service.
19. Remove the engine to transmission brace.
20. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.

22. Remove the heater core hose pipe brace to transmission nut and bolt.
23. Remove the torque converter to flywheel bolts. Using a scribe, mark the flywheel to torque
converter relationship in order to assure the proper reassembly. Refer to Flywheel to Torque
Converter Bolt Replacement .
24. Remove the oil level indicator and the fill tube. Refer to Filler Tube Replacement .
25. Remove the transmission cooler pipes. Plug the pipes in order to prevent leakage. Refer to
Automatic Transmission Oil Cooler Pipes Replacement .
26. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement
27. Remove the vacuum reserve tank.
28. Remove the position transmission jack.
29. Remove the transmission mount to the body bolts. Refer to Transmission Mount
Replacement .
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30. Remove the remaining engine to transmission bolts.

31. Remove the transmission.
32. Flush the transmission cooler and the lines with J 35944 , or equivalent, whenever the
transmission, the pump, the torque converter, or the case has been removed for overhaul or
replacement.
1. Place a thin film of chassis grease GM P/N 1051344 or the equivalent on the torque converter
pilot hub.
Properly seat the torque converter in the oil pump.
2. Position the transmission in the vehicle.
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3. Install the lower engine to transmission bolts.

4. Install the transmission mount to body bolts. Remove the transmission jack.
5. Install the transmission cooler pipes. Refer to Automatic Transmission Oil Cooler Pipes
Replacement .
6. Install the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt
Replacement .
Tighten
Tighten all of the bolts to 62 Nm (46 lb ft). Hand start and tighten the net slot bolt first.
Hand start and tighten the two remaining bolts.
7. Install the oil level indicator and the fill tube. Refer to Filler Tube Replacement .
8. Install the vacuum reserve tank.
9. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
10.
11.
12.
13.
Install the transmission converter cover.

Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
Install the drive axles. Refer to Drive Axle in Drive Axle On-Vehicle Service.
Install the left suspension support assembly. Refer to Control Arm and/or Suspension
Support in Front Suspension.
14. Install the left stabilizer shaft frame bushing nuts. Refer to Stabilizer Shaft in Front
Suspension.
15. Install the stabilizer shaft link pin bolt. Refer to Stabilizer Link in Front Suspension.
16. Install the engine to the transmission brace.
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17. Install both of the ball joints to the control arms. Refer to Ball Joint in Front Suspension.
18. Connect the ABS wheel speed sensor harnesses. Refer to Front Wheel Speed Sensor in
Antilock Brake System and Enhanced Traction System.
19. Install the right and the left side splash shields.
20. Install the heater core pipe brace to the transmission nut and the bolt.
21. Install both of the tire and the wheel assemblies. Refer to Wheel Installation in Tires and
Wheels.
23. Install the upper engine to transmission bolts.

24. Install the shift linkage to the transmission.
25. Install the following wire connectors:

The TCC connector
The Park/Neutral start and back-up lamp switch
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26. Install the wiring harness and the nut securing the harness to the transmission.
27. Remove the J 28467-360 .

28. Install the rubber hose to the transmission vent pipe.
29.
30.
31.
32.
33.
34.
35.
Install the vacuum modulator vacuum line.

Install the air intake duct. Refer to Engine Controls.
Refill the transmission with the proper fluid.
Adjust the shift linkage.
Inspect the oil level.
Ensure that there are no oil leaks.
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1996 Buick Skylark
Transmission Replacement (LD9)

Removal Procedure
J 28467-360 Engine Support Fixture
J 35944 Cooler Flushing Tool
Remove the intake air duct. Refer to Engine Controls.
Remove the cable control cover.
Remove the throttle cable.
Remove the shift cable and the bracket.
Remove the throttle cable from the throttle body.
Remove the vacuum lines.
Remove the electrical connections.
Remove the power steering pump and set aside. Refer to Power Steering Pump Assembly
(2.4L) in Power Steering Gear and Pump.
10. Remove the oil fill tube. Refer to Filler Tube Replacement .
11. Install the J 28467-360 .
2.
3.
4.
5.
6.
7.
8.
9.
12. Remove the top engine to transmission bolts.

Information.
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14. Remove the front tire and wheel assemblies. Refer to Wheel Removal in Tires and Wheels.
15. Remove the left splash shield.
16. Remove both of the front ABS wheel speed sensors and the harness from the left suspension
support. Refer to Front Wheel Speed Sensor in Antilock Brake System and Enhanced Traction
System.
17. Remove both of the lower ball joints. Refer to Ball Joint in Front Suspension.
18. Remove the stabilizer shaft links. Refer to Stabilizer Link in Front Suspension.
19. Remove the front air deflector.
20. Remove the left suspension support. Refer to Control Arm and/or Suspension Support in
Front Suspension.
21. Remove both of the drive axles. Refer to Drive Axle in Drive Axle On-Vehicle Service.
22. Remove the engine to transmission brace.
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24. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
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25. Remove the flywheel to torque converter bolts. Refer to Flywheel to Torque Converter Bolt
Replacement .
26. Remove the transmission cooler pipes. Refer to Automatic Transmission Oil Cooler Pipes
Replacement .
27. Remove the ground wires from the engine to the transmission bolt.
28. Remove the cooler pipe brace.
29. Remove the exhaust brace.
30.
31.
32.
33.
Remove the
Support the
Remove the
Remove the
bolts from the engine and the transmission mount.

transmission with a jack.
transmission mount to body bolts.
heater core hose pipe brace to transmission nut and bolt.
34. Remove the remaining engine to transmission bolts.

35. Remove the transmission assembly.
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36. The transmission cooler and the lines should be flushed with J 35944 , or equivalent,
Document ID: 105988
Page 4 of 6
whenever the transmission has been removed for overhaul or replacement of the torque
converter, the pump, or the case.
1. Place a thin film of grease GM P/N 1051344 or the equivalent on the torque converter pilot
knob. Properly seat the torque converter in the oil pump.
2. Install the transmission assembly into position with the jack while installing the right drive
axle.
3. Install the lower engine to transmission bolts in the proper location.
4. Install the transmission mount to body bolts.

5. Install the engine and the transmission mount bolts.
6. Install the exhaust brace.
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Document ID: 105988
Page 5 of 6
7. Install the cooler pipe brace.

8. Install the ground wires at the engine to transmission bolt.
9. Install the transmission cooler pipes. Refer to Automatic Transmission Oil Cooler Pipes
Replacement .
10. Apply adhesive/sealant compound GM P/N 12345493 or the equivalent on the flywheel to
torque converter bolts.
11. Install the flywheel to torque converter bolts. Refer to Flywheel to Torque Converter Bolt
Replacement .
12. Install the flywheel cover.
13. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
14. Install the engine to transmission brace.

15. Install the drive axles. Refer to Drive Axle in Drive Axle On-Vehicle Service.
16. Install the left suspension support. Refer to Control Arm and/or Suspension Support in Front
Suspension.
17. Install the front air deflector.
18. Install the stabilizer shaft links. Refer to Stabilizer Link in Front Suspension.
19. Install the lower ball joints. Refer to Ball Joint in Front Suspension.
20. Connect both the ABS wheel speed sensors. Refer to Front Wheel Speed Sensor in Antilock
Brake System and Enhanced Traction System.
21. Install the left splash shield.
22. Install the heater core pipe brace nut and the bolt.
23. Install both of the tire and the wheel assemblies. Refer to Wheel Installation in Tires and
Wheels.
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Document ID: 105988
Page 6 of 6
Important: Install the bolts in the proper location.

25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Install the top engine to transmission bolts in the proper location.

Remove the engine support fixture.
Install the oil fill tube. Refer to Filler Tube Replacement .
Install the power steering pump assembly and adjust the belt. Refer to Power Steering Pump
Assembly (2.4L) in Power Steering Gear and Pump.
Connect the electrical connections.
Install the vacuum lines.
Install the throttle cable to throttle body.
Install the shift cable and the bracket.
Install the throttle cable.
Install the cable control cover.
Install the intake air duct. Refer to Engine Controls.
Fill the transmission with the proper fluid.
Adjust the shift linkage.
Inspect for oil leaks. Check the oil level.
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Document ID: 74288
Page 1 of 3

1996 Buick Skylark
Transmission Overhaul
In order to overhaul, follow the sequence below.
1. Torque Converter Disassemble
2. Transmission Holding Fixture Assemble
3. Vacuum Modulator and Valve Disassemble
4. Reverse Servo Disassemble
5. Forward Servo Disassemble
6. Bottom Pan and Filter Disassemble
7. Oil Filter Inspection
8. Accumulator Assembly, 2-1 Band Servo Disassemble
9. Control Valve Body Cover and Gasket Disassemble
10. Wiring Harness Disassemble
11. Oil Pump Disassemble
12. Control Valve Body and Spacer Plate Disassemble
13. Oil Pump Drive Shaft Removal
14. Vehicle Speed Sensor Disassemble
15. Output Shaft Disassemble
16. Front Differential Carrier End Play Check
17. Manual Valve Link and Fluid Dam Removal
18. Case Cover and Gaskets Disassemble
19. 4th Clutch Components Disassemble
20. Drive Link Stretch Check
21. Drive Sprocket, Driven Sprocket, and Drive Link Disassemble
22. Driven Sprocket Support Disassemble
23. 2nd Clutch and Input Clutch Removal
24. Reverse Band Disassemble
25. Reverse Reaction Drum Removal
26. Input Clutch Housing End Play Check
27. Case Extension Housing Disassemble
28. Differential Carrier Components Disassemble
29. Input and Reaction Carrier Disassemble
30. Reaction Sun Gear and Manual 2-1 Band Disassemble
31. 1-2 Support Drum and Forward Band Disassemble
32. Differential Carrier Internal Gear Disassemble
33. Park System Components Disassemble
34. Case Assembly Inspection
35. Case Components Disassemble
36. Case Components Assemble
37. Torque Converter Fluid Seal Removal
38. Drive Sprocket Support Disassemble
39. Drive Sprocket Support Assemble
40. Torque Converter Oil Seal Assemble
41. Park System Components Assemble
42. Differential Carrier Internal Gear Assemble
43. Differential Carrier Inspection
44. Differential Carrier Disassemble
45. Differential Carrier Assemble
46. Vehicle Speed Sensor Reluctor Wheel Disassemble
47. Vehicle Speed Sensor Reluctor Wheel Assemble
48. Differential Carrier Components Assemble
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49. Case Extension Assemble
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Document ID: 74288
Page 2 of 3
50. Input Clutch Housing End Play Tool Assemble

51. Forward Band Assemble
52. 1-2 Support Roller Clutch Disassemble
53. 1-2 Support Roller Clutch Assemble
54. 1-2 Support Roller Clutch Functional Check
55. 1-2 Support Drum Assemble
56. 2-1 Manual Band Assemble
57. Reaction Sun Gear and Drum Assemble
58. Input and Reaction Carrier Pinion End Play Check
59. Input and Reaction Carrier Assemble
60. Reverse Reaction Drum Assemble
61. Input and Third Sprag Clutches Disassemble
62. Input and Third Sprag Clutches Assemble
63. Input and Third Sprag Clutches Functional Check
64. Input Clutch and Third Clutch Disassemble
65. Input Clutch Housing Assembly Inspection
66. Input Clutch Housing Retainer and Ball Disassemble
67. Input Clutch Housing Retainer and Ball Assemble
68. Input Clutch and Third Clutch Assemble
69. Input Clutch and Third Clutch Functional Air Check
70. Input Clutch Housing Oil Seal Rings Assemble
71. Input Clutch Housing and Sprag Clutches Assemble
72. Input Clutch Housing End Play Check
73. 2nd Clutch Disassemble
74. 2nd Clutch Housing Assembly Inspection
75. Second Clutch Housing Retainer/Ball Disassemble
76. Second Clutch Housing Retainer/Ball Assemble
77. 2nd Clutch Assemble
78. Reverse Band Assemble
79. Driven Sprocket Support Components Disassemble
80. Driven Sprocket Support Components Inspection
81. Driven Sprocket Support Bearing Disassemble
82. Driven Sprocket Support Bearing Assemble
83. Driven Sprocket Support Components Assemble
84. 4th and 2nd Clutch Functional Air Check
85. Second, Input, and Sprag Clutches Assemble
86. Driven Sprocket Support Assemble
87. Drive Sprocket and Turbine Shaft Disassemble
88. Drive Sprocket and Turbine Shaft Assemble
89. Drive and Driven Sprocket Components Assemble
90. 4th Clutch Components Assemble
91. Case Cover Components Disassemble
92. Case Cover Components Inspection
93. Case Cover Bearing Disassemble
94. Case Cover Bearing Assemble
95. Drive Axle Oil Seal Removal - Left Side
96. Drive Shaft Oil Seal Assemble - Left Side
97. Case Cover Components Assemble
98. Case Cover and Gaskets Assemble
99. Manual Valve Link and Fluid Dam Assemble
100. Differential Carrier End Play Check
101. Output Shaft Bearing Disassemble
102. Output Shaft Assemble
103. Right Drive Shaft Oil Seal Disassemble
104. Right Drive Shaft Oil Seal Assemble
105. Vehicle Speed Sensor Assemble
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10/14/2010
Document ID: 74288
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
Page 3 of 3
Control Valve Body Clean

Control Valve Body Inspection
Control Valve Body Disassemble
Control Valve Body Assemble
Oil Pump Shaft Bearing Disassemble
Oil Pump Shaft Bearing Assemble
Oil Pump Drive Shaft Assemble
Control Valve Body and Spacer Plate Assemble
Transmission Fluid Pump Disassemble
Transmission Fluid Pump Assemble
Wiring Harness Assemble
Control Valve Body and Gasket Assemble
Thermo Element Adjustment
2-1 Manual Band Servo Disassemble
2-1 Manual Band Servo Assemble
Accumulator Components Disassemble
Accumulator Components Assemble
Accumulator Assembly, 2-1 Band Servo Assemble
Oil Pan and Filter Assemble
Forward Band Servo Components Disassemble
Forward Band Servo Assemble
Reverse Band Servo Components Disassemble
Reverse Band Servo Assemble
Vacuum Modulator Inspection
Vacuum Modulator and Valve Assemble
Transmission Holding Fixture Disassemble
Torque Converter Inspection
Torque Converter Assemble
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10/14/2010
Document ID: 10103
Page 1 of 1

1996 Buick Skylark
Parts Cleaning and Inspection

Service Precautions
1. Use the following safety equipment as appropriate:
Safety glasses
Safety shoes
2.
3.
4.
5.
6.
7.
8.
9.
Gloves
Keep the work area clean.
Keep the tools clean.
Clean the exterior of the transmission before removing parts.
Do not use wipe cloths or rags.
Do not use solvents on rubber seals or plastic/Teflon thrust washers.
Blow out all of the passages with compressed air.
Clean out the small passages with a fine wire.
Handle the parts carefully in order to prevent damage.
Notice: The assembly of some components will require the use of an assembly lube. Always
use J 36850 Transjel or petroleum jelly during assembly. Greases other than the
recommended assembly lube will change the transmission fluid characteristics and cause
undesirable shift conditions and/or filter clogging.
10. When installing screws, bolts or studs into aluminum, always dip the threads into
transmission fluid.
Lubricate all of the internal parts with transmission fluid during assembly.
11.
12.
13.
14.
Always use a torque wrench for the proper torque.

Recondition damaged or stripped aluminum threads with thread inserts.
Replace all of the gaskets and O-ring seals. Do not use gasket cement or sealers.
Replace the Teflon and the rubber lip seals only when necessary. Always use the
appropriate seal installers.
Inspection Procedure
1. Inspect the manual linkage for wear at the pivoting points and bent or broken links and rods.
2. Inspect the following items:
Seals
Gasket
O-rings
3. Check the mating surfaces for the following defects:
Nicks
Cuts
Damage
4. Inspect the snap rings for expansion or compression, distortion, nicks, and proper ring to
groove fit.
5. Inspect the bearings and thrusts surfaces for wear, scoring, and pitting.
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10/14/2010
Document ID: 36024
Page 1 of 1

1996 Buick Skylark
Torque Converter Disassemble

Caution: The torque converter weighs approximately 65 lbs. Personal injury may result if you lift
the torque converter improperly.
1. Remove the torque converter assembly (1).
2. Remove the turbine shaft O-ring seal (520).
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10/14/2010
Document ID: 57929
Page 1 of 1

1996 Buick Skylark
Transmission Holding Fixture Assemble

Tools Required
J 3289-20 Holding Fixture Base
J 28664-B Transmission Holding Fixture
1. Install J 28664-B onto the transmission.

2. Install the transmission and holding fixture into J 3289-20 .
3. Insert the pin into J 3289-20 in order to hold the transmission in the desired position.
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10/14/2010
Document ID: 36027
Page 1 of 1

1996 Buick Skylark
Vacuum Modulator and Valve Disassemble
1.
2.
3.
4.
Remove the modulator retainer bolt (30).

Remove the modulator retainer (31).
Remove the modulator assembly (32) by pulling the assembly straight out.
Use a small magnet tool in order to remove the modulator valve (34) by pulling the valve
straight out.
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Document ID: 36028
Page 1 of 2

1996 Buick Skylark
Reverse Servo Disassemble
1. Use a long screwdriver in order to depress the reverse band servo cover (40) by prying
against the transmission holding fixture.
2. Use a small screwdriver in order to pry out the retaining ring (39) from the reverse band
servo cover.
3. Remove the long screwdriver. The servo assembly will push the servo cover (40) up.
4. Use a small screwdriver in order to pull the servo cover O-ring seal (41) out through the slot
in the case.
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5. Use side cutting pliersin
order
to cut
theCorporation.
servo cover
seal (41).
General
Motors
All O-ring
rights reserved.
2010
10/14/2010
Document ID: 36028
Page 2 of 2
6. Grasp one end of the cut seal (41) and pull it out of the servo cover.
7.
8.
9.
10.
Remove
Remove
Remove
Remove
the
the
the
the
servo cover (40).

reverse band servo o-ring seal (41).
reverse band servo assembly (42-48).
reverse band servo piston spring (49).
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10/14/2010
Document ID: 36029
Page 1 of 2

1996 Buick Skylark
Forward Servo Disassemble
1. Position the transmission so that the oil pan is facing up.

2. Use a long screwdriver in order to compress the forward band servo assembly cover (13) by
prying against the work bench.
3. Hold the servo assembly compressed.
4. Remove the three forward band servo cover bolts (12).

5. Remove the long screwdriver. The servo assembly will push the servo cover out. If the servo
cover does not push out, tap it with a rubber mallet.
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6. Remove the servo cover
(13)
and remove
the coverAll
seal
(14).
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Motors Corporation.
rights
reserved.
2010
10/14/2010
Document ID: 36029
Page 2 of 2
7. Remove the servo assembly (15-21).

8. Remove the piston spring (22) from the forward band servo.
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10/14/2010
Document ID: 36030
Page 1 of 1

1996 Buick Skylark
Bottom Pan and Filter Disassemble
1.
2.
3.
4.
Remove the 20 oil pan bolts (23).

Remove the oil pan (24).
Remove the oil pan gasket (25).
Use a screwdriver in order to pry the oil filter assembly (100) out of the case. Do not damage
the case sealing surface.
5. Use a small screwdriver in order to pry the oil filter seal assembly (101) out of the case. Do
not damage the case sealing surface.
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Document ID: 36031
Page 1 of 1

1996 Buick Skylark
Transmission Fluid Filter Inspection
1. Inspect the oil pan magnet (26) for steel particles. Excessive amounts of steel shavings
indicate internal transmission damage.
2. Use a screwdriver or side cutters in order to open the oil filter assembly (100), by cutting or
prying the metal crimping away from the top of the filter and by pulling the filter apart.
3. Inspect the filter (100) for excessive amounts of the following:
Clutch plate assembly fiber material, indicating clutch distress
Bronze slivers, indicating bushing wear
Steel particles, indicating internal transmission damage
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10/14/2010
Document ID: 38822
Page 1 of 2

1996 Buick Skylark
Accumulator Assembly and 2-1 Band Servo Removal
1. Remove the four indicated accumulator cover bolts (131) from the 1-2 and 2-3 accumulator
cover (132).
2. Remove the three indicated bolts (103) from the manual 2-1 band servo cover (104).
3. Use a large screwdriver in order to gently pry the lube oil pipe retainer (129) from the case.
4. Remove the lube oil pipe (130) from the front differential carrier internal gear lube hole.
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10/14/2010
Document ID: 38822
Page 2 of 2
Notice: Do not twist or damage the pipe assembly when removing the pipe assembly.
5. Remove the 1-2 and 2-3 accumulator assembly (132-140), the pipe assembly (124-126) and
the manual 2-1 band servo cover (104).
6. Remove the manual 2-1 band servo assembly (106-116) out of the case at the same time.
7. Remove the cover seal (105) from the manual 2-1 band servo assembly.
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10/14/2010
Document ID: 38824
Page 1 of 1

1996 Buick Skylark
Control Valve Body Cover and Gasket Disassemble
1. Position the transmission so that the cover of the control valve body is facing upward.
On transmissions with a cast aluminum cover:
- 11 flanged bolts (52)
- 2 stud bolts (58)
- 4 TORX bolts (57)
On transmissions with a stamped steel cover:
- 15 flanged bolts (52)
- 2 stud bolts (58)
- 6 nuts and washers (50 & 51)
3. Remove the control valve body cover (53).
4. Remove the inner (55) and the outer (54) gaskets from the control valve body cover. In
some models, remove the seal (59).
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10/14/2010
Document ID: 38825
Page 1 of 2

1996 Buick Skylark
Wiring Harness Disassemble
1. Use a small screwdriver in order to disconnect the wiring harness assembly (224) from the
electrical connector (35) in the case.
2. Use a small screwdriver in order to disconnect the wiring harness assembly at the following
locations:
The 1-2 and 3-4 shift solenoid valve (315)
The 2-3 shift solenoid valve (315)
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The TCC PWM solenoid
valve
(325)
General
Motors Corporation.
2010
10/14/2010
Document ID: 38825
Page 2 of 2
The TCC apply solenoid valve (315)

The TFT sensor (391) located on the case cover or on the spacer plate
The wiring harness clip
3. Remove the wiring harness assembly (224).
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10/14/2010
Document ID: 38827
Page 1 of 1

1996 Buick Skylark
Oil Pump Disassemble
1. Remove the 13 indicated oil pump bolts (204-207).
2. Remove the wiring harness clip (226).

3. Lift the oil pump assembly (300) off of the control valve body.
4. Set the pump assembly upside down on its cover. The pump will be fully disassembled later.
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10/14/2010
Document ID: 38828
Page 1 of 2

1996 Buick Skylark
Control Valve Body and Spacer Plate Disassemble
1. Remove the indicated control valve body bolts (375-380).
2. Remove the control valve body assembly (300).

3. Remove the six ball check valves (372, 373) from the top of the spacer plate (370).
4. Remove the spacer plate (370), remove the gaskets (369, 371), and remove the screens
(374).
5. Remove the case cover pin (410).
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10/14/2010
Document ID: 38828
Page 2 of 2
6. Remove the four ball check valves (372) from the case cover.
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Document ID: 38829
Page 1 of 1

1996 Buick Skylark
Oil Pump Drive Shaft Removal
Remove the oil pump drive shaft assembly (227) from the case cover (400).
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10/14/2010
Document ID: 38830
Page 1 of 1

1996 Buick Skylark
Vehicle Speed Sensor Disassemble
1. Position the transmission so that the vehicle speed sensor (10) is facing up.
2. Remove the vehicle speed sensor bolt (9).
Important: Handle the speed sensor carefully.
3. Remove the vehicle speed sensor (10).
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10/14/2010
Document ID: 38831
Page 1 of 2

1996 Buick Skylark
Output Shaft Disassemble

Tools Required
J 34757 Snap Ring Remover and Installer
1. Remove the four case extension bolts (5).

2. Remove the case extension assembly (6) and remove the extension seal (8).
3. Leave the front differential carrier thrust washer (715) and the bearing (714) on the carrier.
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10/14/2010
Document ID: 38831
Page 2 of 2
4. Rotate the differential carrier until you can see the end of the output shaft.
5. Rotate the output shaft while holding the carrier, until the opening on the drive shaft snap
ring is visible.
6. Use J 34757 in order to push the snap ring (512) partially off of the output shaft.
7. Remove the snap ring with needle nose pliers.
Important: Be careful not to damage the bearing on the output shaft.

8. Pull the output shaft (510) out of the transmission.
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10/14/2010
Document ID: 38832
Page 1 of 3

1996 Buick Skylark
Front Differential Carrier End Play Check

Tools Required
J 8001 Dial Indicator Set
J 25025-7A Dial Indicator Stand
4t80E Alignment Pin Set and Mounting Post
J 26958 Output Shaft Loading and Aligning tool
J 26958-10B Adapter Plug
J 28585 Snap Ring Remover
J 38385 Output Shaft Loading Tool Adapter
1. Make sure that the thrust washer (714) and the bearing (715) are still on the front
differential carrier.
2. Install the case extension seal (8) onto the case extension (6).
3. Install the case extension assembly (6) onto the transmission (3).
4. Install only two of the four case extension bolts (5).
Tighten
Do not torque the bolts. Tighten them only until the case extension is fully seated.
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10/14/2010
Document ID: 38832
5.
6.
7.
8.
Page 2 of 3
Position the transmission so that the case extension is facing upward.

Install 4t80E , J 26958-10B , and J 8001 .
Set the dial indicator to zero.
Use J 28585 or a large screwdriver in order to lift the front differential carrier. Pry up on the
vehicle speed sensor reluctor wheel through the sensor hole in the case extension.
9. Note the dial indicator reading before changing the carrier thrust washer (714):
If the dial indicator reading is less than 0.12 mm (0.005 in), install the next smaller size
thrust washer, then recheck.
If the dial indicator reading is greater than 0.62 mm (0.025 in), install the next larger size
If the dial indicator reading is 0.12-0.62 mm (0.005-0.025 in), the thrust washer is
correct.
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Document ID: 38832
Page 3 of 3
10. Remove J 8001 and J 25025-7A .

11. Install J 26958 , J 26958-10B , and J 38385 onto the case extension (6).
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Document ID: 38833
Page 1 of 2

1996 Buick Skylark
Manual Valve Link and Fluid Dam Removal
1. Remove the manual shift detent bolt (805).

2. Remove the manual shift detent assembly (804).
3. Compress the manual valve link spring (403).

4. Lift the manual valve link (402) off of the manual valve (404).
5. Position the manual valve link (402) so that the valve will not interfere with the case cover
removal.
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10/14/2010
Document ID: 38833
Page 2 of 2
6. Remove the oil dam (27) from the case.
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Document ID: 38834
Page 1 of 2

1996 Buick Skylark
Case Cover and Gaskets Disassemble
1. Remove the indicated case cover bolts (434, 435, 436, 450, 804, 805).
Important: Be sure to hold the manual valve (404) in place.

2. Lift the case cover assembly (400) off of the case.
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10/14/2010
Document ID: 38834
Page 2 of 2
3. Remove the upper (430) and the lower (429) case cover gaskets.
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Document ID: 38835
Page 1 of 1

1996 Buick Skylark
4th Clutch Components Disassemble
1.
2.
3.
4.
Remove
Remove
Remove
Remove
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the
the
the
the
fourth clutch backing plate (500).

fourth clutch fiber and steel plates (501, 502).
fourth clutch shaft assembly (504).
drive link lube scoop (608).
10/14/2010
Document ID: 38836
Page 1 of 1

1996 Buick Skylark
Drive Link Stretch Check
1. Make sure that the driven sprocket support (609) and both sprockets (516, 506) are fully
seated.
2. Pull the drive link (507) toward the case at the indicated location.
3. Measure the distance between the case and the drive link:
If the measurement is 3.2 mm (1/8 in) or greater, reuse the drive link.
If the measurement is less than 3.2 mm (1/8 in), replace the drive link.
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10/14/2010
Document ID: 38837
Page 1 of 1

1996 Buick Skylark
Drive Sprocket, Driven Sprocket, and Drive Link

Disassemble
1. Remove the fourth clutch shaft thrust washer (505).

2. Remove the drive sprocket thrust washer (514). The washer may be stuck to the case cover.
3. Note the location of the master link on the drive link assembly:
This link is a different color than the rest
This link will be facing either up or down towards the case
The drive link assembly must be in the same position during installation
4. Lift the drive, driven sprockets and the drive link assembly out of the case:
Lift both sides evenly
If necessary, tap the turbine shaft gently with a rubber mallet.
5. Remove the thrust washers (517, 508) from the drive and driven sprocket. These washers
may be stuck to the sprockets.
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10/14/2010
Document ID: 38838
Page 1 of 1

1996 Buick Skylark
Driven Sprocket Support Disassemble
1. With your fingers, insert two 13 mm channel plate bolts (434) into the driven sprocket
support assembly (609).
2. Grasp the bolts and lift the support assembly from the case.
3. Remove the thrust washer (611) from the second clutch housing. The washer may be stuck
to the support assembly.
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10/14/2010
Document ID: 38839
Page 1 of 2

1996 Buick Skylark
2nd Clutch and Input Clutch Removal

Tools Required
J 33381-A Final Drive Remover and Installer
1. Adjust the collar on tool J 33381-A to the 4T60-E CLUTCH & DRUM setting. Make sure that
the threaded rod is fully loosened.
2. Install J 33381-A into the second clutch housing assembly (617).

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10/14/2010
Document ID: 38839
Page 2 of 2
3. Tighten the threaded rod of J 33381-A until the rod is finger tight.
4. Lift up J 33381-A with the second clutch (617) and the input clutch assemblies (632)
attached. The sprag clutch assemblies will also be attached.
5. Place the complete assembly on the bench.
6. Loosen the threaded rod of J 33381-A .
7. Remove J 33381-A from the assembly.
8. Lift the second clutch housing assembly (617) off of the input clutch housing.
9. Remove the input clutch housing thrust bearing (629) from the input housing.
10. Remove the selective thrust washer (630) from the input clutch housing.
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10/14/2010
Document ID: 38840
Page 1 of 1

1996 Buick Skylark
Reverse Band Removal
Tilt the band in order to disengage the band from the anchor pin in the case. Remove the reverse
band assembly (615).
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10/14/2010
Document ID: 38841
Page 1 of 1

1996 Buick Skylark
Reverse Reaction Drum Removal
Remove the reverse reaction drum (669).
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10/14/2010
Document ID: 38842
Page 1 of 5

1996 Buick Skylark
Input Clutch Housing End Play Check

Tools Required
J 26958 Output Shaft Loading and Aligning Tool
J 33386-A Input Shaft End Play Tool
1. Adjust the collar on tool J 33381-A to the 4T60-E CLUTCH & DRUM setting.
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2. Install J 33381-A into the input clutch housing assembly (632).

4. Use J 33381-A in order to lift the input clutch housing assembly (632). The sprag clutch
assemblies will also be attached.
5. Install the assembly (632) into the case. Be sure that the assembly is down all the way.
Important: The tool J 38385 (3) is used on a standard duty transmission, and J 43425 (3)
is used on a heavy duty transmission.
6. Install J 38385 (3) for a standard duty transmission or J 43425 (3) for a heavy duty
transmission.
Important: The tool J 26958-10B (2) is model specific and can be used on a standard duty
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Document ID: 38842
Page 3 of 5
and a heavy duty transmission. This tool has a small end (4) and a larger end (5). Standard
duty would use the smaller end (4) facing down, and a heavy duty would use the larger
end (5) facing down.
7. Install J 26958-10B (2) depending on model. Stadard duty uses this tool with the smaller
end (4) facing down. Heavy duty uses this tool with the larger end (5) facing down.
Important: Install bolts and tighten securely to prevent tool deflection during end play
measurement.
8. Install J 26958 (1) onto the case extension (6).
9.
10. Using two bolts, install J 33386-A onto the case.

11. Tighten the bolts in order to securely hold J 33386-A .
12. Tighten J 26958 finger tight in order to eliminate differential carrier end play.
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13. Insert the thrust washer (630) from the input clutch housing (632) into J 33386-A as
indicated. If the thrush washer will not fit into J 33386-A , select the next size smaller thrust
washer and recheck.
14. Use a feeler gage in order to measure the clearance between J 33386-A and the thrust
washer (630).
If the clearance is less than 0.0521 mm (0.006 in), use the current size thrust washer.
If the clearance is 0.0521 mm (0.006 in) or more, select the next size larger thrust
washer and recheck.
15. Refer to the Thrust Washer Selection Guide in End Play Specifications .
16. Remove J 33386-A .

18. Install J 33381-A into the input clutch housing (632).
21. Remove the assembly (632) from the case.
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22. Position the transmission so that the oil pan is facing down.
23. Remove J 26958 (1), J 26958-10B (2), and J 38385 (3) or J 43425 (3).
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Page 1 of 1

1996 Buick Skylark
Case Extension Disassemble
1.
2.
3.
4.
Remove
Remove
Remove
Remove
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the
the
the
the
two case extension bolts (5).

case extension assembly (6) and remove the seal (8).
differential carrier thrust washer (715).
differential carrier thrust bearing (714).
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1996 Buick Skylark
Differential Carrier Components Disassemble
1. Remove the
2. Remove the
stuck to the
3. Remove the
4. Remove the
5. Remove the
6. Remove the
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differential carrier assembly (700).

thrust bearing (698) from the differential carrier sun gear. The bearing may be
carrier assembly.
differential carrier sun gear (697).
park gear (696).
thrust bearing (695) from the differential carrier internal gear.
shaft differential carrier sun gear (689).
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Document ID: 38845
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1996 Buick Skylark
Input and Reaction Carrier Disassemble
1. Position the transmission so that the case cover joint is facing upward.
2. Remove the input carrier assembly (672).
3. Remove the input carrier, reaction carrier lube dam (673). The dam may be stuck to the
input carrier assembly.
4. Remove the thrust bearing (674) from the reaction carrier.
5. Remove the reaction carrier assembly (675).
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1996 Buick Skylark
Reaction Sun Gear and Manual 2-1 Band Removal
1. Remove the thrust bearing (676) from the reaction sun gear.
2. Remove the reaction sun gear assembly (678).
3. Tilt the band in order to disengage the manual 2-1 band assembly (680) from the anchor pin.
Remove the manual 2-1 band assembly from the case.
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Document ID: 38848
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1996 Buick Skylark
1-2 Support Drum and Forward Band Removal

Tools Required
J 38358-A 1-2 Support Remover and Installer
1. Install J 38358-A onto the 1-2 support drum assembly (681-687).

2. Lift J 38358-A with the 1-2 support drum out of the case.
3. Tilt the forward band assembly (688) in order to disengage the band from the anchor pin in
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Document ID: 38848
Page 2 of 2
the case. Remove the forward band assembly.
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Document ID: 38850
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1996 Buick Skylark
Differential Carrier Internal Gear Removal

Tools Required
1. Remove the thrust washer (691) from the differential carrier internal gear.
2. UseJ 28585 or a large screwdriver in order to remove the differential carrier internal gear
snap ring (692).
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3. Lift the differential carrier internal gear assembly (693) out of the case by depressing the
park pawl assembly in order to clear the case.
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1996 Buick Skylark
Park System Components Disassemble
1. Disassemble the manual valve link and spring from the manual shift detent lever.
2. Remove the nut (803) for the manual shift detent lever from the manual shift shaft (807).
3. Remove the manual shift detent lever (802) and remove the park pawl actuator assembly
(800).
4. Use side cutting pliers in order to remove the manual shift shaft pin (801):
Do not cut through the pin
Protect the case with a piece of wood or rubber
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Document ID: 38853
5.
6.
7.
8.
9.
10.
Page 2 of 2
Position the transmission so that the reverse band servo bore is facing upward.
Pull the manual shift shaft (807) out of the case.
Use a small screwdriver in order to pry the manual shift shaft seal (806) from the case:
Remove the park pawl actuator guide pin (808).
Remove the park pawl actuator guide assembly (809) from the case.
Remove the actuator guide seal (810) from the guide.
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1996 Buick Skylark
Case Assembly Inspection
1. Inspect the components that are still on the transmission case for the following conditions:
Loose, cross-threaded, or damaged oil cooler pipe fittings
A loose, missing, or damaged transmission name plate
2. Inspect the transmission case for the following conditions:
Gasket sealing surfaces that are damaged or which have porosity
Bolt or screw holes that are stripped or damaged (repair with a thread insert)
Damaged or porous case oil passages
Damaged snap ring grooves or housing splines
Loose, missing, or damaged band anchor pins
Damaged or porous case surfaces
Plugged drain back holes for the torque converter oil seal
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3. Inspect the components that are still on the transmission case for the following conditions:
A loose, plugged, or damaged transmission vent assembly
A loose, cross-threaded, or damaged oil pressure test hole plug
A damaged transmission electrical connector or seal
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Document ID: 38856
Page 1 of 1

1996 Buick Skylark
Case Components Disassemble
1. Use a small screwdriver in order to pry open the tab of the electrical connector assembly
(35).
2. Remove the electrical connector assembly (35) and the O-ring (36).
3. Check to see if the vent is damaged or plugged. If so, use a channel locks type of pliers and
a large screwdriver in order to remove the vent assembly (37).
4. Remove the oil pressure test hole plug (38).
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1996 Buick Skylark
Case Components Assemble

Tools Required
J 36850 Assembly Lubricant
1. Install a new O-ring seal (36) onto the electrical connector assembly (35). Lubricate with J
36850 or equivalent.
2. Install the electrical connector assembly (35) into the case. Lubricate with J 36850 or
equivalent.
3. Use a hammer and a punch in order to install the vent assembly (37), if necessary.
4. Install the oil pressure test hole plug (38).
Tighten
Tighten the test hold plug to 11 Nm (97 lb in).
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1996 Buick Skylark
Torque Converter Fluid Seal Removal

Tools Required
J 23129 Converter Housing Seal Remover
1. Assemble J 6125-1B and J 23129 .

Important: Do not damage the transmission case during the removal of the torque
converter seal assembly.
2. Remove the oil seal assembly (525) from the case:
Use J 6125-1B and J 23129 in order to remove the seal
Install J 23129 between the seal and stator support
Alternately, use a large, flat blade screwdriver in order to pry out the seal. Use a block of
wood to pry against
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Document ID: 38862
Page 1 of 2

1996 Buick Skylark
Drive Sprocket Support Disassemble

Tools Required
J 23907 Universal Slide Hammer and Puller
J 26941 Drive Sprocket Support Bearing Remover
1. Inspect the drive sprocket support (522) for the following conditions:
Damaged splines
A damaged drive sprocket support bearing
A damaged turbine shaft bushing (pressed inside the support)
2. Remove the drive sprocket support bearing only if the bearing is damaged.
3. Remove the drive sprocket support assembly only if the support is damaged.
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4. Assemble J 23907 and J 26941 .

5. Use J 23907 and J 26941 in order to remove the bearing assembly (521) from the drive
sprocket support.
6. Remove the four drive sprocket support bolts (524).

7. Remove the drive sprocket support assembly (522).
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1996 Buick Skylark
Drive Sprocket Support Assemble

Tools Required
J 28677 Drive Sprocket Support Bearing Installer
J 36850 Transmission Assembly Lubricant
1. Assemble J 28677 and J 8092 .

2. Lubricate drive sprocket support bearing (521) with J 36850 .
Important: When installing the new bearing the part number should be visible (facing
upward).
3. Using the assembled tool, press in the drive sprocket support bearing (521).
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4. Install the drive sprocket support assembly (522).

5. Install the four drive sprocket support bolts (524).
Tighten
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Page 1 of 1

1996 Buick Skylark
Torque Converter Fluid Seal Assemble

Tools Required
J 28540-A Converter Seal Installer
Notice: Install the seal onto the tool before installing into the case to prevent damage to the seal.
Use J 28540-A and a mallet in order to install the torque converter oil seal (525).
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Document ID: 38870
Page 1 of 3

1996 Buick Skylark
Park System Components Assemble
1. Inspect the park system components for the following conditions:

A worn park pawl actuator guide (809).
A cracked or bent park pawl actuator assembly (800).
A damaged manual shift shaft detent lever (802).
A worn, stripped, or bent manual shift shaft (807).
A bent or damaged manual valve link (402).
A kinked or bent manual valve link spring (403).
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2. Use a 9/16 in socket and a hammer in order to install the manual shift shaft seal assembly
(806) into the case.
3. Install a new park pawl actuator guide O-ring seal (810) onto the park pawl actuator guide
(809).
4. Install the actuator guide assembly into the case.
5. Align the slot for the actuator guide pin (808) in the park pawl with the pin hole in the case.
6. Use a mallet in order to install the actuator guide pin (808).
7. Install the manual shift shaft (807) into the case.

8. Align the groove for the manual shift shaft pin with the pin hole in the case.
9. Use a mallet in order to install the shaft pin (801).
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10. Position the transmission so that the case cover flange is facing upward.
11. Install the park pawl actuator assembly (800).
12. Assemble the manual shift shaft detent lever (802) onto the actuator assembly and onto the
manual shift shaft (807).
13. Install the nut (803) on the manual shift shaft.
Tighten
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Document ID: 38873
Page 1 of 2

1996 Buick Skylark
Differential Carrier Internal Gear Assemble

Tools Required
1. Inspect the differential carrier internal gear assembly (693) for the following conditions:
Damaged or worn bushings
Plugged lube oil holes
Damaged case splines
Damaged or worn gear teeth
A damaged or worn park pawl assembly (694)
A damaged snap ring (692)
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2. Install the differential carrier internal gear assembly (693) into the case. Align the park pawl
assembly with the park pawl actuator assembly.
3. Use J 28585 or a long screwdriver in order to install the snap ring (692) into the case as
shown.
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Document ID: 38875
Page 1 of 3

1996 Buick Skylark
Differential Carrier Inspection
1. Inspect the differential carrier assembly (700) for the following conditions:
Damaged or worn teeth, bearing rollers, washers, or pins on the differential planetary
pinion gear
Damaged or worn teeth or splines on the final drive sun gear (697)
Damaged or worn teeth, splines, or thrust washers on the differential side gear
Damaged or worn teeth, thrust washers, or shaft on the differential pinion gear
Damaged or worn lugs or splines on the parking gear (696)
A damaged vehicle speed sensor reluctor wheel
Damaged internal gear/parking gear thrust bearing (695), differential carrier/sun gear
thrust bearing (698) or differential carrier/case thrust bearing (715)
A damaged or worn differential carrier/case selective thrust washer (714)
A damaged differential/final drive carrier housing (700)
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2. Inspect the final drive sun gear shaft (689) for the following conditions:
Damaged or worn splines
Cracks at lube oil holes
Damaged or worn bearing journals
3. Use a feeler gauge in order to measure the end play of the differential carrier planetary
pinion gear.
Specification
End play should be 0.24-0.63 mm (0.009-0.025 in).
4. If the end play check or the component inspection indicates a condition, repair the
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Document ID: 38875
Page 3 of 3
differential/final drive carrier assembly (700).
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Document ID: 38876
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1996 Buick Skylark
Differential Carrier Disassemble
1. Use a screwdriver in order to remove the snap ring (699) from the front differential carrier.
Important: Keep all washers and bearings together with the planetary pinion gear and pin.
The pinion gears, washers, and bearings must be reinstalled in the original locations.
2. Remove the first planetary pinion by removing the following parts:
2.1. The planetary pinion gear pin (712)
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2.2. The pinion thrust washers (708)

2.3. The pinion gear roller bearings (709)
2.4. The bearing roller spacer (710)
2.5. The pinion (711)
3. Remove the remaining planetary pinions in the same way.
4. Remove the differential carrier sun gear thrust bearing assembly (698).
5. Place the final drive carrier components into an oil pan in order to make sure that none of the
bearing rollers are lost.
6. Use a drift punch and a mallet in order to remove the differential pinion gear shaft pin (702).
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10/14/2010
Document ID: 38876
7.
8.
9.
10.
11.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
differential
differential
differential
differential
differential
Page 3 of 3
pinion shaft (701).

pinion gears (704).
pinion gear thrust washers (703).
side gears (705).
side gear thrust washers (706).
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10/14/2010
Document ID: 38877
Page 1 of 4

1996 Buick Skylark
Differential Carrier Assemble

Tools Required
J 36850 Assembly Lubricant (or equivalent)
1. Affix the differential side gear thrust washers (706) to the side gears (705). Apply J 36850 or
equivalent.
2. Install the side gears (705) with the thrust washers into the differential carrier housing
(700).
3. Affix the differential pinion thrust washers (703) to the pinion gears (704). Apply J 36850 or
equivalent.
4. Install the pinion gears with thrust washers into the differential carrier housing (700). Rotate
the pinion gears into position.
5. Install the differential pinion shaft (701) into the differential carrier housing.
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6. Align the hole in the pinion gear shaft (701) to the hole in the differential carrier housing
(700).
7. Use a drift punch and a mallet in order to install the pinion gear shaft pin (702) into the
differential carrier housing (700).
8. Apply J 36850 or equivalent to the inside of a differential carrier planetary pinion gear (711).
9. For each planetary pinion gear, insert a bearing roller spacer (710) onto the pin (712). The
spacer must be inserted between the two rows of bearing rollers.
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Document ID: 38877
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10. For each planetary pinion gear, assemble the bearing rollers (709) into the gear (711) one at
a time.
Use plenty of J 36850 or equivalent in order to aid assembly
Use a washer (708) on the bottom of the pinion gear (711) in order to help hold the
bearing rollers (709) in place.
The number of rollers in the pinion gear is model dependent:
- The 3.05/3.06 and 3.29/3.33 ratio differential carriers have two rows of 22 rollers (44
total)
- The 2.86/2.84 ratio differential carriers have two rows of 18 rollers (36 total)
Occasionally twist the pinion gear pin (712) in order to help align the rollers
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11. Install the differential carrier sun gear thrust bearing (698) into the carrier housing.
12. Remove each planetary pinion gear pin (712) from its pinion gear (711). Be careful not to
move the rollers out of position.
13. Affix two pinion gear thrust washers (708) on each side of the pinion gear (711). Apply J
36850 or equivalent.
Important: Make sure that the pinion is installed in the same way that it was removed. If
the gear is installed upside down, noise may result, because of the change in the gear wear
pattern.
14. Install the pinion gear assemblies (711) into the carrier housing (700).
15. Install each planetary pinion gear pin (712).
16. Install the snap ring (699) over the planetary pinion gear pins.
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Document ID: 38879
Page 1 of 1

1996 Buick Skylark
Vehicle Speed Sensor Reluctor Wheel Disassemble

Tools Required
J 22888-D Universal Bearing Puller
1. Do not remove the vehicle speed sensor reluctor wheel (713) unless the wheel is damaged.
2. Use J 22888-D and a piece of flat metal stock in order to remove the vehicle speed sensor
reluctor wheel (713).
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Document ID: 38880
Page 1 of 1

1996 Buick Skylark
Vehicle Speed Sensor Reluctor Wheel Assemble
1. Warm the vehicle speed sensor reluctor wheel before installation

2. Use a plastic mallet in order to install the vehicle speed sensor reluctor wheel (713) onto the
differential carrier housing. Tap evenly around the reluctor wheel with the mallet until fully
seated.
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Document ID: 38881
Page 1 of 2

1996 Buick Skylark
Differential Carrier Components Assemble

Tools Required
1. Assemble the carrier/sun gear thrust bearing (698), the final drive sun gear (697) with the
chamfered side toward the parking gear (696) into the differential/final drive carrier
assembly (700).
2. Assemble the parking gear (696) onto the final drive sun gear shaft (689)
3. Assemble the final drive sun gear shaft/parking gear assembly (689/696) into the final drive
sun gear (697).
Important: Apply J 36850 or equivalent to the parking gear side of the bearing (695).
4. Assemble the internal gear/parking gear thrust bearing (695) to the parking gear (696).
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Document ID: 38881
Page 2 of 2
5. Install the differential/final drive carrier assembly into the case.
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Page 1 of 2

1996 Buick Skylark
Case Extension Assemble

Tools Required
J 26958 Output Shaft Loading Tool
J 26958-10A Adapter Plug
1. Inspect the case extension assembly (6) for the following conditions:
A damaged or porous sealing surface for the case extension seal
A damaged or porous sealing surface for the vehicle speed sensor
A damaged or porous sealing surface for the right drive shaft oil seal assembly
Damaged bolt holes
A worn or damaged front differential carrier bushing (7A) or output shaft bearing
assembly (7B)
A porous or damaged case extension housing
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2. Install the differential carrier/case selective thrust washer (714) onto the differential/final
drive carrier assembly (700).
3. Install the thrust bearing (715) onto the differential/final drive carrier assembly (700).
4. Affix the seal (8) onto the case extension (6).
5. Install the case extension assembly (6) onto the case (3).
6. Install only two case extension bolts (5) for later removal.
Tighten
Tighten the bolts until the extension is flush to the case.
7. Perform end play check, refer to Differential Carrier End Play Check.
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Document ID: 38885
Page 1 of 1

1996 Buick Skylark
Input Clutch Housing End Play Tool Assemble

Tools Required
J 26958 Output Shaft Loading Tool
J 26958-10B Adaptor Plug
J 38385 Output Shaft Loading Tool Adaptor
Important: Install the bolts and tighten all bolts in order to prevent tool deflection during end play
measurement.
Install the input clutch housing assembly end play tool as shown. You will use this tool in order to
perform the selective washer check for the input clutch housing.
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Document ID: 38887
Page 1 of 2

1996 Buick Skylark
Forward Band Assemble
1. Inspect the forward band assembly (688) for the following conditions:
Damaged or severely worn friction material
Damaged apply or anchor pin features
2. Inspect the thrust washer (691) from the differential carrier internal gear for damage.
3. Position the transmission case so that the flange for the case cover is facing up.
4. Install the thrust washer (691) for the differential carrier internal gear into the case. Position
as indicated.
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Document ID: 38887
Page 2 of 2
5. Install the forward band assembly (688) into the case.

Locate the band assembly onto the forward band anchor pin
Position the band apply pin feature in the opening of the case
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10/14/2010
Document ID: 38888
Page 1 of 1

1996 Buick Skylark
1-2 Support Roller Clutch Disassemble
1. Use a small screwdriver in order to gently pry the thrust bearing (685) off of the 1-2 support
drum (687).
2. Lift the 1-2 clutch roller assembly (683) out of the 1-2 support drum.
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Document ID: 38889
Page 1 of 2

1996 Buick Skylark
1-2 Support Roller Clutch Assemble
1. Inspect the 1-2 support roller clutch components for the following conditions:
A scored or burned contact surface for the manual 2-1 band on the 1-2 support drum
(687)
A damaged or worn forward drum bushing
A damaged or worn inner race of the 1-2 support roller clutch
A damaged or worn 1-2 clutch roller assembly (683)
A damaged thrust bearing (685)
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Document ID: 38889
Page 2 of 2
2. Install the 1-2 clutch roller assembly (683) into the 1-2 support drum.
Important: Note the position of the cage assembly to the inner race.
3. Install the thrust bearing (685) onto the 1-2 support drum (687). Press down with hand
pressure only.
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Document ID: 38890
Page 1 of 1

1996 Buick Skylark
1-2 Support Roller Clutch Functional Check
1. Position the 1-2 support drum assembly (687) on the bench as shown.
2. Install the reaction sun gear assembly (678) into the 1-2 support drum (687).
3. Rotate the components as indicated by the arrows:
The roller clutch should move freely in the indicated directions
The roller clutch should lock in the direction opposite of that indicated
4. If the roller clutch does not function as described, reassemble the clutch correctly, or replace
the assembly.
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10/14/2010
Document ID: 38892
Page 1 of 1

1996 Buick Skylark
1-2 Support Drum Assemble

Tools Required
J 38358-A 1-2 Support Remover/Installer
Use J 38358-A in order to assemble the 1-2 support drum assembly (681-687) into the case.
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10/14/2010
Document ID: 38893
Page 1 of 1

1996 Buick Skylark
Manual 2-1 Band Assemble
1. Inspect the 2-1 manual band (680) for the following:

Cracked or separated friction material
Burnt friction material
Cracks around the apply lugs
2. Squeeze the manual 2-1 band assembly (680) and install the assembly into the case.
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General
Motors Corporation.
2010
3. Position the band on the
anchor
pin.
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Document ID: 38894
Page 1 of 2

1996 Buick Skylark
Reaction Sun Gear and Drum Assemble
1. Inspect the reaction sun gear and drum assembly (678) for the following:
Worn or scored bushings
Damaged reaction sun gear teeth
The band apply area of the drum for discoloration or wear
The welds connecting the sun gear to the drum for voids or cracks
A worn or damaged 1-2 support outer race
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Document ID: 38894
Page 2 of 2
2. Install the reaction sun gear and drum assembly (678) into the case.
3. Check that the lugs engage with the 1-2 support roller clutch inner race.
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Document ID: 38896
Page 1 of 1

1996 Buick Skylark
Input and Reaction Carrier Pinion End Play Check
1. Use feeler gages in order to check for excessive pinon gear end play in the input carrier
assembly (672) and in the reaction carrier assembly (675).
2. End play should measure 0.23-0.77 mm (0.009-0.030 in).
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Document ID: 38897
Page 1 of 2

1996 Buick Skylark
Input and Reaction Carrier Assemble

Tools Required
J 36850 Transjel
1. Inspect the thrust bearings (671, 674, 676) for the following:
A damaged cage
Damaged or missing rollers
2. Inspect the reaction carrier assembly (675) for damage to the pinion/internal gear teeth.
3. Inspect the input carrier assembly (672) for damage to the pinion/spline teeth.
4. Inspect the lube dam (673) for the following:
Cracks
Damage
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Document ID: 38897
Page 2 of 2
5. Affix the thrust bearing (676) onto the reaction carrier (675). Use J 36850 or equivalent in
order to retain the bearing.
6. Install the reaction carrier (675) into the case and rotate the carrier so that the pinions
engage the reaction sun gear.
7. Affix the thrust bearing (674) into the input carrier (675). Use J 36850 or equivalent in order
to retain the bearing.
8. Install the lube dam (673) into the reaction carrier assembly (675). Use J 36850 or
equivalent in order to retain the dam.
9. Insert the input carrier assembly (672) into the case and rotate the carrier so that the
pinions engage the reaction carrier internal gear.
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10/14/2010
Document ID: 38899
Page 1 of 1

1996 Buick Skylark
Reverse Reaction Drum Assemble
1. Inspect the reverse reaction drum (669) for the following:

Cracks
Damaged splines
Distortion
2. Install the reverse reaction drum (669) into the case and engage the drum onto the input
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carrier splines as shown.
10/14/2010
Document ID: 38901
Page 1 of 2

1996 Buick Skylark
Input and Third Sprag Clutches Disassemble
1. Disassemble the input and third sprag clutch assemblies (653, 665) from the input clutch
Important: After you remove the spiral lock retaining ring (717), discard the ring. Use a
new spiral lock retaining ring when you reassemble the sprag.
2. Use a tapered blade screwdriver in order to remove the spiral lock retaining ring (717) from
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Document ID: 38901
Page 2 of 2
the input clutch sprag outer race retainer.

3. Remove the third clutch sprag assembly (665) and the input clutch sprag assembly (653)
from the input and third clutch sprag inner race (661).
4. Remove the input and third clutch sprag inner race (661) and the input sun gear spacer
(667) from the input sun gear (668).
5. Remove the 3rd clutch sprag outer race retainer (718).

6. Remove the input and third clutch sprag end bearings (719) and the input and third clutch
sprag center bearing (721) from the sprag outer races (653, 665).
Important: Do not disassemble the sprag elements.
7. Remove the 3rd clutch and input clutch sprag assemblies (720, 722) from the sprag outer
races (653, 665).
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10/14/2010
Document ID: 38903
Page 1 of 4

1996 Buick Skylark
Input and Third Sprag Clutches Assemble

Tools Required
J 41022-A Spiral Snap Ring Installer
1. Inspect the outer races of the input sprag (653) and third sprag (665) for the following:
Worn or damaged splines
Scoring on the inside diameter of the races
Wear or cracks
2. Inspect the sprag elements for flat spots.
3. Inspect the cage assemblies (720, 722) for distortion or broken ribbon tabs.
4. Inspect the end bearings (719) and the center bearing (721) for cracks.
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Document ID: 38903
Page 2 of 4
5. Inspect the input sun gear spacer (667) for the following:
Wear or cracks
6. Inspect the input sun gear (668) for the following:
Plugged lube holes or cracks
7. Position the input clutch sprag on a suitable flat work surface with the lip facing downwards.
8. Insert the end bearing (719) for the input and third clutch sprag into the outer race (665).
9. Insert the input sprag assembly (722) into the outer race (665).
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Document ID: 38903
Page 3 of 4
10. Position the third clutch sprag outer race (653) on a suitable flat work surface with the lube
dam side facing down.
Important: The lip on the third sprag must be in the up position.
11. Insert the center bearing (721) of the input and third clutch sprag into the third clutch.
Important: The lip on the sprag cage must be in the up position.
12. Install the third sprag assembly (720) into the third clutch outer race (653).
13. Insert the end bearing (719) into the third clutch outer race.
14. Install the input sprag assembly (665) onto the inner race (661) of the input and third clutch
sprag.
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Document ID: 38903
Page 4 of 4
15. Install the third sprag assembly (653) onto the inner race (661).
16. Affix the retainer (718) onto the third clutch sprag outer race.
Important: Use new snap rings. Do not attempt to reinstall old rings.
Important: Be sure that you seat the spiral snap ring in the groove on the inner race. The
tabs and the slots on the snap ring must lock.
17. Attach J 41022-A to an arbor press. Use this tool combination and a small flat blade
screwdriver in order to install the snap ring (717) onto the input clutch sprag.
18. Assemble the spacer (667) onto the input sun gear (668).
19. Assemble the input and third sprag clutch assemblies (665, 653) onto the input sun gear
(668).
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10/14/2010
Document ID: 38904
Page 1 of 1

1996 Buick Skylark
Input and Third Sprag Clutches Functional Check
1. Hold the input sun gear (668) stationary in the position shown.
2. The third sprag clutch outer race (653) should rotate only in the direction shown by the
arrow and not in the opposite direction.
3. The input sprag clutch assembly (665) should rotate only in the direction shown by the arrow
and not in the opposite direction.
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10/14/2010
Document ID: 38907
Page 1 of 5

1996 Buick Skylark
Input and 3rd Clutch Disassemble

Tools Required
J 23327 Clutch Spring Compressor
J 25018-A Clutch Spring Compressor Adapter
1. Use a flat blade screwdriver in order to remove the retaining ring (659) from the input shaft
and housing assembly (632).
2. Remove the input clutch backing plate (658).
3. Remove all of the input clutch plate assemblies (656, 657).
4. Remove the input clutch waved plate (655) and the input clutch apply plate (654).
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Page 2 of 5
5. Use a flat blade screwdriver in order to remove the retaining ring (649) from the input shaft
and housing assembly (632).
6. Remove the third clutch backing plate (648)
7. Remove the third clutch plate assemblies (646, 647).
8. Remove the third clutch waved plate (645).
9. Remove the input shaft thrust bearing assembly (644).
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10. Use J 23327 and J 25018-A in order to compress the third clutch spring retainer and guide
assembly.
Important: Do not overexpand the retaining ring during removal.
11. Use J 8059 in order to remove the retaining ring (640) from the input shaft and housing
assembly.
12. Remove J 23327 and J 25018-A from the input shaft and housing assembly.
13. Remove the third clutch retainer and guide spring assembly (643).
14. Remove the third clutch piston and seal assembly (642).
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15. Use J 23327 in order to compress the input clutch spring and retainer assembly.
Important: Do not overexpand the retainer ring during removal.
16. Use J 8059 in order to remove the retainer ring (640) from the input shaft and housing
assembly.
17. Remove J 23327 from the input shaft and housing assembly.
18. Remove the third clutch piston housing (639).

19. Remove the input clutch spring and retainer assembly (637).
20. Remove the input clutch piston assembly (636).
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21. Remove the input clutch piston outer seal (635).
22. Remove the third clutch piston inner seal (641).

23. Remove the third clutch housing O-ring seal (638).
24. Remove the input clutch piston inner seal (634).
Important: Do not damage the grooves on the shaft when you remove the oil seal rings.
25. Cut the input shaft oil seal rings (628).
26. Remove the input shaft oil seal rings (628).
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10/14/2010
Document ID: 38909
Page 1 of 2

1996 Buick Skylark
Input Clutch Housing Assembly Inspection
1. Inspect the input clutch housing assembly (632) for the following:
Plugged feed passages
Input shaft bushing (631) wear
Seal ring groove nicks or burrs
Cracks or blocked fluid passages in the input shaft
Damage or wear to the thrust bearing (723) in the input clutch housing
2. With the ball check valve assembly in its seated position in transmission fluid, Inspect the
assembly for leaks.
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Document ID: 38909
Page 2 of 2
3. Inspect the input clutch piston (636) for the following:

Cracks or damage to seal grooves
Wear on piston lugs
4. Inspect the input clutch spring and retainer assembly (637) for a damaged cage and
distorted or missing springs.
5. Inspect the third clutch piston housing (639) for damage.
6. Inspect the third clutch spring retainer and guide assembly (643) for a damaged cage and
distorted or missing springs.
Important: Do not attempt to reuse the third clutch piston and seal assembly.
7. Replace the third clutch piston and seal assembly (642).
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8. Inspect the input shaft thrust bearing assembly (644) for damage or wear.
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Document ID: 38911
Page 1 of 1

1996 Buick Skylark
Input Clutch Housing Retainer and Ball Disassemble
Important: Perform this procedure only if the inspection or leak check procedure indicated a
problem.
Use a 6.25 mm (1/4 in) drift and mallet in order to remove the ball check valve assembly (633)
from the input clutch housing.
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10/14/2010
Document ID: 38914
Page 1 of 1

1996 Buick Skylark
Input Clutch Housing Retainer and Ball Assemble
Use a 9.5 mm drift and mallet in order to assemble a new ball check valve assembly (633) into the
input clutch housing.
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10/14/2010
Document ID: 38915
Page 1 of 6

1996 Buick Skylark
Input and 3rd Clutch Assemble

Tools Required
J 37361 Input Clutch Inner Piston Seal Protector
J 37362 Third Clutch Inner Piston Seal Protector
J 23327 Clutch Spring Compressor
J 25018-A Clutch Spring Compressor Adapter
1. Use transmission fluid in order to lubricate the new input clutch piston inner seal (634).
2. UseJ 37361 in order to install the new seal.
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Document ID: 38915
Page 2 of 6
3. Insert a new third clutch housing O-ring seal (638) in the input shaft and housing assembly.
4. Use transmission fluid in order to lubricate the new third clutch piston inner seal (641).
5. Use J 37362 in order to install the seal in the input shaft and housing assembly (632).
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Document ID: 38915
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6. Use transmission fluid in order to lubricate the new input clutch piston outer seal (635).
7. Insert the new seal onto the input clutch piston assembly (636).
8. Install the input clutch piston assembly (636) into the input shaft and housing assembly.
9. Install the input clutch spring and retainer assembly (637) into the input shaft and housing
assembly.
10. Install the third clutch piston housing (639) into the input shaft and housing assembly.
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Document ID: 38915
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11. Use J 23327 and J 8059 in order to install the third clutch piston housing retaining ring (640)
in the input shaft and housing assembly.
12. Remove the J 23327 .
13. Use transmission fluid in order to lubricate the new third clutch piston and seal assembly
(642). Install the third clutch piston and seal assembly (642) into the input shaft and housing
assembly (632).
14. Install the third clutch spring retainer and guide assembly (643) into the input shaft and
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Document ID: 38915
Page 5 of 6
15. Use J 23327 , J 25018-A and J 8059 in order to install the third clutch spring retainer and
guide assembly retaining ring (640).
16. Remove the J 23327 .
17. Insert the third clutch waved plate (645) into the input shaft and housing assembly (632).
Important: Place the first externally splined plate with its steel side against the waved plate.
Place the fiber side of all plates face upward.
18. Insert the third clutch plates assemblies into the input housing. Start by inserting a third
clutch plate (646) with external splines. Alternate with the internally splined clutch plates
(647).
19. Insert the third clutch backing plate (648) with the word UP facing upward.
20. Insert the retaining ring (649) into the input shaft and housing assembly (632).
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21. Insert the input clutch apply plate (654) into the input shaft and housing assembly (632), so
that the notched side of the teeth are facing downward against the retaining ring on the third
clutch backing plate.
22. Install the input clutch waved plate (655).
23. Install the input clutch plates (656, 657) starting with an input clutch steel plate (657) and
alternating with input clutch fiber plate assemblies (656).
24. Insert the input clutch backing plate (658) with the tapered side of the teeth facing upward.
25. Insert the retaining ring (659) in the input shaft and housing assembly (632).
26. Insert the input shaft thrust bearing assembly (644).
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Document ID: 38917
Page 1 of 1

1996 Buick Skylark
Input and 3rd Clutch Functional Air Check
Notice: Do not exceed the recommended amount of air pressure or it may damage or cause
seals to roll.
1. Use a rubber tipped air nozzle in order to apply a maximum 138 kPa (20 psi) at each
indicated fluid passage.
2. Listen for the following:
The third clutch (1) assembly to apply
The input clutch (2) assembly to apply
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10/14/2010
Document ID: 38918
Page 1 of 3

1996 Buick Skylark
Input Clutch Housing Fluid Seal Ring Assemble

Tools Required
J 34741-A Input Seal Installer contains:
J 34741-1 Adjustable Seal Protector
J 34741-2 Seal Pusher
J 34741-3 Seal Sizer
1. Install J 34741-1 into the input clutch housing (632). Adjust J 34741-1 so that the bottom of
the seal installer aligns with the lowest seal ring groove.
2. Use transmission fluid in order to lubricate the oil seal ring for the input clutch housing.
Position the ring on the J 34741-1 .
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3. Position J 34741-2 onto the J 34741-1 . Push the seal (628) into the seal ring groove.
4. Repeat this procedure for the second and the third seal rings (628).
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Document ID: 38918
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5. Remove the input seal installer.

6. Use a twisting motion in order to assemble J 34741-3 over the seals.
7. Leave J 34741-3 in place until the input clutch housing assembly (632) is assembled into the
transmission.
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10/14/2010
Document ID: 38920
Page 1 of 1

1996 Buick Skylark
Input Clutch Housing and Sprag Clutches Assemble
1. Use a small screwdriver in order to align the teeth of the input clutch plate assembly and the
third clutch plate assembly. This will ease installation of the sprag clutch assembly.
Important: Make sure that the sprag clutch assembly is fully seated into the housing.
2. Insert the combined input sprag clutch (665), third sprag clutch (653) and input sun
gear (668) assembly into the input clutch housing assembly (632).
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10/14/2010
Document ID: 38921
Page 1 of 5

1996 Buick Skylark
Input Clutch Housing End Play Check

Tools Required
J 26958 Output Shaft Loading and Aligning Tool
J 33386-A Input Shaft End Play Tool
1. Adjust the collar on tool J 33381-A to the 4T60-E CLUTCH & DRUM setting.
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10/14/2010
Document ID: 38921
Page 2 of 5
2. Install J 33381-A into the input clutch housing assembly (632).

5. Install the assembly (632) into the case. Be sure that the assembly is down all the way.
Important: The tool J 38385 (3) is used on a standard duty transmission, and J 43425 (3)
is used on a heavy duty transmission.
6. Install J 38385 (3) for a standard duty transmission or J 43425 (3) for a heavy duty
transmission.
Important: The tool J 26958-10B (2) is model specific and can be used on a standard duty
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10/14/2010
Document ID: 38921
Page 3 of 5
and a heavy duty transmission. This tool has a small end (4) and a larger end (5). Standard
duty would use the smaller end (4) facing down, and a heavy duty would use the larger
end (5) facing down.
7. Install J 26958-10B (2) depending on model. Stadard duty uses this tool with the smaller
end (4) facing down. Heavy duty uses this tool with the larger end (5) facing down.
Important: Install bolts and tighten securely to prevent tool deflection during end play
measurement.
8. Install J 26958 (1) onto the case extension (6).
9. Using two bolts, install J 33386-A onto the case.

10. Tighten the bolts in order to securely hold J 33386-A .
11. Tighten J 26958 finger tight in order to eliminate differential carrier end play.
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Document ID: 38921
Page 4 of 5
12. Insert the thrust washer (630) from the input clutch housing (632) into J 33386-A as
indicated. If the thrush washer will not fit into J 33386-A , select the next size smaller thrust
washer and recheck.
13. Use a feeler gage in order to measure the clearance between J 33386-A and the thrust
washer (630).
If the clearance is less than 0.0521 mm (0.006 in), use the current size thrust washer
If the clearance is 0.0521 mm (0.006 in) or more, select the next size larger thrust
washer and recheck
14. Refer to the Thrust Washer Selection Guide in End Play Specifications .
15. Remove J 33386-A .

17. Install J 33381-A into the input clutch housing (632).
20. Remove the assembly (632) from the case.
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Document ID: 38921
Page 5 of 5
22. Remove J 26958 (1), J 26958-10B (2), and J 38385 (3) or J 43425 (3).
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Document ID: 38923
Page 1 of 2

1996 Buick Skylark
2nd Clutch Disassemble
1. Use a flat blade screwdriver in order to remove the retaining ring (627) from the second
clutch housing.
2. Remove the second clutch backing plate (626). Remove the alternating second clutch fiber
plates (624). Remove the second clutch steel plates (625).
3. Remove the second clutch apply plate (716). Remove the second clutch waved plate (623).
4. Use a flat blade screwdriver in order to remove the retaining ring (622) from the second
clutch housing.
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5. Remove the second clutch
(621). All rights reserved.
Generalassembly
Motors Corporation.
2010spring
10/14/2010
Document ID: 38923
Page 2 of 2
6. Remove the second clutch piston assembly (620).
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Document ID: 38924
Page 1 of 2

1996 Buick Skylark
2nd Clutch Housing Assembly Inspection
1. Inspect the second clutch housing assembly (617) for the following:
A leaking or damaged ball check valve in the second clutch housing. Turn the housing in
order to seat the check ball. Use transmission fluid in order to check for leaks.
Scored or worn bushings
Discolored band surface or wear on the drum caused by excess heat
Flatness of the band surface on the drum
Damaged reverse reaction drum splines
Cracks in welds
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Document ID: 38924
Page 2 of 2
2. Inspect the backing plate (626) and the waved plate (623) of the second clutch for cracks or
heat spots.
3. Inspect the steel plates (625) and the apply plate (716) of the second clutch for wear.
4. Inspect the fiber plates (624) of the second clutch for wear, flaking, or lining separation.
5. Inspect the spring assembly (621) of the second clutch for damage to the ring cage. Check
for distorted or missing springs.
6. Inspect the spring snap ring (622) of the second clutch for damage. Inspect the snap ring
(627) of the second clutch backing plate for damage.
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10/14/2010
Document ID: 38926
Page 1 of 1

1996 Buick Skylark
Second Clutch Housing Retainer/Ball Disassemble
Important: If the ball check valve assembly (618) does not leak, do not remove the assembly.
Use a 6.25 mm (1/4 in) drift and a mallet in order to remove the ball check valve assembly (618)
from the second clutch housing (617).
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10/14/2010
Document ID: 38927
Page 1 of 1

1996 Buick Skylark
Second Clutch Housing Retainer/Ball Assemble
Use a 9.5 mm (3/8 in) drift and a mallet in order to assemble a new ball check valve assembly
(618) in the second clutch housing (617).
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10/14/2010
Document ID: 38930
Page 1 of 2

1996 Buick Skylark
2nd Clutch Assemble

Tools Required
J 38678-A Second Clutch Piston Assembly Tool contains:
J 38678-A -1 Protector
J 38678-A -2 Installer
J 38678-A -3 Adapter
1. Install J 38678-A -3 into the new second clutch piston assembly (620).
2. Install the piston and J 38678-A -3 into J 38678-A -1 protector.
3. Install the piston assembly into the second clutch housing assembly (617).
Important: Carefully center the inner seal protector onto the hub by pushing down on the
center of J 38678-A -1.
4. Insert the legs of J 38678-2 installer into the slots of J 38678-A -1 protector.
5. Using your hand, press down on the installer J 38678-A -2 until the piston is seated.
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Document ID: 38930
Page 2 of 2
6. Assemble the second clutch spring assembly (621) into the second clutch housing assembly
(617).
7. Install the snap ring (622) in the second clutch housing.
8. Install the waved plate (623) into the second clutch housing (617).
9. Install the apply plate (716) into the second clutch housing, with the marking DN or DOWN
toward the piston.
10. Install a fiber plate (624), followed by a steel plate (625) into the second clutch housing.
11. Assemble remaining plates, alternating between steel and fiber.
12. Install the backing plate (626) into the second clutch housing, with the machined side facing
up and the smooth side facing down.
13. Install the snap ring (627) into the second clutch housing.
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10/14/2010
Document ID: 38932
Page 1 of 2

1996 Buick Skylark
Reverse Band Assemble
1. Inspect the reverse band assembly (615) for the following:

Cracks
Scoring
Lining separation
Wear of the fiber material
2. Inspect the apply lug for cracks.
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10/14/2010
Document ID: 38932
Page 2 of 2
3. Install the reverse band assembly (615) into the case with the band end aligned on the
anchor pin in the case.
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10/14/2010
Document ID: 38935
Page 1 of 2

1996 Buick Skylark
Driven Sprocket Support Components Disassemble

Tools Required
J 4670-01 Clutch Spring Compressor
1. Use J 4670-01 clutch spring compressor in order to compress the fourth clutch spring
assembly (602). Remove the snap ring (601) from the driven sprocket support assembly.
2. Remove the spring assembly (602) and remove the fourth clutch piston assembly (603) from
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Document ID: 38935
Page 2 of 2
the driven sprocket support assembly (609).
3. Remove the outer seal (604) from the fourth clutch piston (603).
4. Remove the inner seal (605) for the fourth clutch piston from the driven sprocket support
assembly hub.
5. Remove the oil seal rings (613) and the four-lobed ring seal (612) from the driven sprocket
support.
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10/14/2010
Document ID: 38936
Page 1 of 1

1996 Buick Skylark
Driven Sprocket Support Components Inspection
1. Inspect the driven sprocket support assembly (609) for the following:
Worn or cut oil seal rings (612)
Rolled or cut second clutch housing oil seal ring seals (613)
Damage to the piston seal surface in the driven sprocket support assembly
Blocked or porous oil passages in the driven sprocket support assembly
2.
3.
4.
5.
6.
A leaking or missing cup plug

Inspect the fourth clutch piston (603) for damage.
Inspect the thrust washer (611) from the second clutch housing for cracks or distortion.
Inspect the fourth clutch spring assembly (602) for distorted or missing springs.
Inspect the driven sprocket bearing assembly for foreign material and missing, flat, or
damaged rollers.
Replace the Teflon seal rings (613) under the following conditions:
The rings are cut or damaged
You are performing a complete overhaul

7. Inspect all seal ring grooves for debris, burrs, or damage.
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10/14/2010
Document ID: 38941
Page 1 of 1

1996 Buick Skylark
Driven Sprocket Support Bearing Disassemble

Tools Required
J 34129 Bearing Remover
Use J 34129 , J 8092 and a hammer in order to remove the driven sprocket support bearing
assembly from the driven sprocket support assembly (609).
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10/14/2010
Document ID: 38942
Page 1 of 1

1996 Buick Skylark
Driven Sprocket Support Bearing Assemble

Tools Required
J 34126 Sprocket/Remover Bearing Remover
Important: Position the driven sprocket support bearing assembly so that markings on the edge
are facing up.
Use J 34126 (2) , J 8092 (1) and a hammer in order to seat the driven sprocket support bearing
assembly flush with or below the driven sprocket support assembly (609) hub.
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Document ID: 38944
Page 1 of 3

1996 Buick Skylark
Driven Sprocket Support Components Assemble

Tools Required
J 4670-01 Clutch Spring Compressor
1. Use transmission fluid in order to lubricate a new outer seal (604) for the fourth clutch piston
(603). Affix the seal to the piston.
2. Use transmission fluid in order to lubricate a new inner seal (605) for the fourth clutch
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Document ID: 38944
Page 2 of 3
piston. Affix the seal to the driven sprocket support hub.
3. Insert the fourth clutch piston assembly (603) into the driven sprocket support (609) and
align as shown.
4. Insert the fourth clutch spring assembly (602) into the piston.
5. Use J 4670-01 in order to install the fourth clutch spring snap ring (601).
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Document ID: 38944
Page 3 of 3
6. If you are installing new oil seal rings (613) for the second clutch housing, lubricate the
rings. Insert the rings onto the driven sprocket support hub.
7. Affix the four lobed ring seals (612) for the second clutch housing onto the driven sprocket
support hub (609).
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10/14/2010
Document ID: 38947
Page 1 of 2

1996 Buick Skylark
4th and 2nd Clutch Functional Air Check
1. For the purposes of this test, attach the driven sprocket support assembly (609) and the
second clutch housing thrust washer (611) onto the second clutch housing assembly (617).
Important: Air pressure that exceeds recommended intensity may damage the seals or
cause the seals to roll.
2. Apply 138 kPa (20 psi) to the feed holes marked 2 and 4, and listen for the second and
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10/14/2010
Document ID: 38947
Page 2 of 2
fourth clutches to apply.

3. Hold the pressure for five seconds. If the clutches do not apply and hold, then disassemble
the driven sprocket support components. Inspect all of the seals and clutches for proper
assembly. When finished, repeat the functional check.
4. When the clutches apply and hold correctly, remove the driven sprocket support assembly
(609) and the second clutch housing thrust washer (611) from the second clutch housing
assembly (617).
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10/14/2010
Document ID: 38949
Page 1 of 3

1996 Buick Skylark
Second, Input, and Sprag Clutches Assemble

Tools Required
1. Be sure that the selective thrust washer (630) and the thrust bearing assembly (629) for the
input clutch housing are in place.
2. Use a small screwdriver in order to align the second clutch teeth so that they slide onto the
second clutch hub of the input clutch housing assembly (632).
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3. Affix the second clutch housing assembly (617) onto the second clutch hub of the input
clutch housing assembly (632).
5. Install J 33381-A into the second clutch housing assembly (617).

7. Use J 33381-A in order to lift the second clutch housing (617) and the input clutch assembly
(632). The sprag clutch assemblies will also be attached.
Important: After you have installed the housing, confirm that the top of the second clutch is
flush or slightly below the top of the reverse band assembly contact area.
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Document ID: 38949
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8. Install the housing (617) and the assembly (632) into the case. Be sure that the assembly is
down all the way.
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Document ID: 38951
Page 1 of 2

1996 Buick Skylark
Driven Sprocket Support Assemble

Tools Required
1. Use J 36850 or equivalent in order to secure the second clutch housing thrust washer (611)
to the driven sprocket support assembly (609).
2. Finger start two 13 mm channel plate bolts (434) into the driven sprocket support assembly
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Document ID: 38951
Page 2 of 2
(609).
Important: If the driven sprocket support assembly (609) is not flush with or slightly below
the case, then one of the clutches is not fully seated.
3. Using the bolts (434), lift the driven sprocket support assembly (609) into the case and align
as shown. The top of the driven sprocket support assembly (609) should be flush with the
case.
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Document ID: 39283
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1996 Buick Skylark
Drive Sprocket and Turbine Shaft Disassemble
Important: Do not damage the grooves under the oil seal rings.
1. Cut the oil seal rings (513, 519) from the turbine shaft.
2. Remove the oil seal rings.
3. Remove the drive sprocket snap ring (515).

4. Remove the drive sprocket (516) from the turbine shaft (518).
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Document ID: 39284
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1996 Buick Skylark
Drive Sprocket and Turbine Shaft Assemble

Tools Required
J 29569-1 Seal Installer
J 29569-2 Sizing Tool
1. Inspect the driven sprocket (506) for the following:

Worn or chipped teeth
Uniform teeth size
Stripped or damaged splines
Bearing surface damage
2. Inspect the fourth clutch shaft thrust washer (505) and the driven sprocket thrust washer
(508) for wear or cracks.
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3. Inspect the drive sprocket (516) for the following:

Worn or chipped teeth
Uniform teeth size
Bearing surface damage
4. Inspect the turbine shaft (518) for the following:
A cracked sleeve
Damaged bushing journals
5. Inspect the thrust washers (514, 517) for wear or cracks.
6. Insert the turbine shaft (518) into the drive sprocket (516) and attach the snap ring (515).
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7. Install J 29569-1 onto the turbine shaft (518). Coat the tool shaft with J 36850 or equivalent.
8. Slide the turbine shaft seals (513) into position.
9. Use J 29569-2 in order to size the turbine shaft oil seal rings (513).
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10. Install J 29829-1A onto the turbine shaft (518). Coat the tool shaft with J 36850 or
equivalent.
11. Slide the turbine shaft oil seal ring (519) into position.
12. Use J 29829-2 in order to size the turbine shaft oil seal ring (519).
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Document ID: 38958
Page 1 of 2

1996 Buick Skylark
Drive and Driven Sprocket Components Assemble

Tools Required
1. Inspect the drive link assembly (507) for damaged, cracked, or binding links.
2. Use J 36850 or equivalent in order to retain the thrust washer (517) onto the drive sprocket
(516).
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3. Use J 36850 or equivalent in order to retain the thrust washer (508) onto the driven sprocket
support.
Important: The drive link assembly must be installed correctly.
4. Assemble the drive and driven sprockets into the drive link assembly (507) according to one
of the following criteria:
If an old drive link is being reinstalled, put the drive link assembly with the master link
(different color) facing up or down, whichever way it was found during disassembly
If a new drive link assembly is being installed, put the drive link assembly with the master
link facing upward.
5. Install the drive link assembly and the sprockets into the case by hand. A slight rocking
motion may be required in order to work the sprockets into place.
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Document ID: 38961
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1996 Buick Skylark
4th Clutch Components Assemble
1. Inspect the fourth clutch assembly for the following conditions:

Wear or damage to the steel plates (500, 502)
Peened splines, flaking, or worn fiber on the fiber plates (501)
2. Inspect the fourth clutch shaft assembly (504) for the following conditions:
Cut or worn fourth clutch plate splines
Damage or wear to the fourth clutch shaft bushing
A damaged bushing journal
Stripped splines for the input sun gear
Cracks or damage to the hub or shaft
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3. Insert the fourth clutch shaft (504) into the case through the driven sprocket. The shaft must
fully seat into the input sun gear.
4. Insert the drive link lube scoop (608) into the case.
5. Insert a steel fourth clutch plate (502) into the driven sprocket support with the machined
side towards the sprocket.
6. Insert the remaining fourth clutch plates, alternating between fiber plates (501) and steel
plates (502).
7. The clutch plates should align in the driven sprocket support as shown.
8. Insert the fourth clutch reaction plate (500) onto the driven sprocket support.
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Document ID: 38962
Page 1 of 1

1996 Buick Skylark
Case Cover Components Disassemble
Important: Do not remove any of the bore plugs unless inspection indicates that
replacement is necessary.
1. Remove the manual valve (404).
2. Remove the cylinder (421) and the seal (422) for the 3-4 accumulator piston.
3. Remove the outer spring (423), middle spring (424), and inner spring (425) for the 3-4
accumulator piston.
4. Remove the pin (426) for the 3-4 accumulator piston.
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Document ID: 38964
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1996 Buick Skylark
Case Cover Components Inspection
1. Inspect the 3-4 accumulator piston (428) for the following:

Porosity
A scored pin
A nicked groove in the piston sleeve
2. Inspect the piston pin (426) from the 3-4 accumulator for scoring and free movement in the
piston bore.
3. Inspect the springs (423-425) from the 3-4 accumulator for distorted or broken coils.
4. Inspect the piston cylinder (421) from the 3-4 accumulator for the following:
Porosity or cracks
A rough or scored seal surface
A cut seal
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Important: Do not remove the blowoff valves unless the valves are damaged.
5.
6.
7.
8.
9.
Inspect the ball valve spring (418), the bore plug (417), and the ball valve (420) for damage.
Inspect the ball valve spring (406), the bore plug (405), and the ball valve (420) for damage.
Inspect the manual valve (404), the link (402), and the link spring (403) for damage.
Inspect the manual valve (404) for binding or looseness in the case cover assembly (401).
Inspect the case cover plugs, and inspect the orificed cup plug. Correct the following
conditions:
Part is loose
Part is missing
Part is plugged
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Important: Do not remove the bearing unless the bearing is damaged.

10. Inspect the bearing assembly (431) for damage or roughness.
11. Inspect the oil seal (409) for a missing garter spring or for a cut lip seal.
12. Inspect the case cover (401) for the following:
Porosity
Interconnected fluid passages
Cracks or rough machined surfaces
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Document ID: 38965
Page 1 of 1

1996 Buick Skylark
Case Cover Bearing Disassemble
Remove the bearing assembly (431) from the case cover.
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Document ID: 38967
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1996 Buick Skylark
Case Cover Bearing Assemble
Important: Do not bend or damage the bearing during installation.

Install the bearing assembly (431) onto the case cover.
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Document ID: 38987
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1996 Buick Skylark
Drive Axle Oil Seal Removal - Left Side

Tools Required
Use J 23129 and J 6125-1B in order to remove the oil seal assembly (409) from the case cover
(401).
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Document ID: 38989
Page 1 of 1

1996 Buick Skylark
Drive Shaft Oil Seal Assemble - Left Side

Tools Required
J 34115 Axle Seal Installer
Important: When you remove a drive axle from the transmission for any reason, inspect the axle
sealing surface (tripot shank) for corrosion. If corrosion is evident, clean the surface with a 320 grit
cloth or equivalent. Clean off any remaining debris with automatic transmission fluid. Wipe the
surface dry and reinstall the drive axle free of any build up.
Use J 34115 in order to install the oil seal assembly (409) for the front wheel drive shaft.
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Document ID: 38990
Page 1 of 1

1996 Buick Skylark
Case Cover Components Assemble
1.
2.
3.
4.
5.
Install a new seal (427) onto the 3-4 accumulator piston (428).
Insert the 3-4 accumulator piston (428) into the case cover.
Affix a new seal (422) onto the accumulator piston cylinder (421).
Install the springs (423, 424, 425) into the 3-4 accumulator cylinder (421).
Use a slight twisting motion in order to insert the accumulator piston cylinder (421) into the
case cover.
6. Insert the 3-4 accumulator piston pin (426) through the front of the case cover and into the
piston (428).
7. Assemble the manual valve (402, 403, 404) and insert the valve assembly into the case
cover.
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Document ID: 38992
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1996 Buick Skylark
Case Cover and Gaskets Assemble
Important: Do not use any type of adhesive or sealer when assembling the gaskets. You
may use Transjel or equivalent as an aid.
1. Assemble the upper and lower gaskets (430, 429) for the automatic transmission case cover.
2. Hold the manual valve in place and carefully assemble the case cover (400) onto the pins in
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Document ID: 38992
Page 2 of 3
the case.
Important: Do not use an impact wrench in order to tighten cover bolts.

3. Finger start all transmission case cover bolts into the locations noted (434, 436, 805).
4. Use 10 mm and 13 mm sockets in order to tighten all the bolts.

Tighten
Tighten all the bolts to 20.0-27.0 Nm (14.7-20.0 lb ft).
Refer to Fastener Notice .
5. Some transmission models have a temperature sensor (450) which is located in the case
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Document ID: 38992
Page 3 of 3
cover. Install the temperature sensor at this time.
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Document ID: 38993
Page 1 of 2

1996 Buick Skylark
Manual Valve Link and Fluid Dam Assemble
1. Insert the transmission oil dam (27) into the case.
2. Insert the manual valve link and spring assembly into the manual shift shaft detent lever.
3. Pull back the manual valve spring (403) and connect the manual valve link (402) to the
manual valve.
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Document ID: 38993
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4. Attach the manual shift shaft detent assembly (804) to the case with a bolt (805).
Tighten
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Document ID: 38997
Page 1 of 3

1996 Buick Skylark
Differential Carrier End Play Check

Tools Required
J 25025-1 Dial Indicator Stand
J 25025-B Alignment Pin Set and Mounting Post
J 26958 Output Shaft Loading and Aligning tool
J 26958-10A Adapter Plug
1. Make sure that the thrust washer (714) and the bearing (715) are still on the front
differential carrier.
2. Install the case extension seal (8) onto the case extension (6).
3. Install the case extension assembly (6) onto the transmission case.
4. Install only two of the four case extension bolts (5).
Tighten
Do not torque the bolts. Tighten them only until the case extension is fully seated.
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5. Position the transmission so that the case extension is facing upward.

6. Install J 25025-B , J 26958-10A , and J 8001 .
7. Set the dial indicator to zero.
Important: Protect the VSS sensor bore with a piece of wood or rubber while prying.
8. Use J 28585 or a large screwdriver in order to lift the front differential carrier. Pry up on the
vehicle speed sensor reluctor wheel through the sensor hole in the case extension.
9. Note the dial indicator reading before changing the carrier thrust washer (714):
If the dial indicator reading is less than 0.12 mm (0.005 in), install the next smaller size
If the dial indicator reading is greater than 0.62 mm (0.025 in), install the next larger size

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Document ID: 38997
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If the dial indicator reading is 0.12-0.62 mm (0.005-0.025 in), the thrust washer is
correct.
Remove J 8001 and J 25025-1 .
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Document ID: 38998
Page 1 of 1

1996 Buick Skylark
Output Shaft Bearing Disassemble
1. Remove the fourth clutch bearing (511) from the output shaft.
2. Remove the drive axle snap ring (509) from the output shaft.
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Document ID: 39000
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1996 Buick Skylark
Output Shaft Assemble
1. Inspect the output shaft and the bearing for the following:
A cracked or deformed bearing cage
Damaged bushing journals
Stripped splines
A damaged retainer ring groove
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2. Affix the drive axle retainer ring (509) and the output shaft differential in board snap ring
(512) onto the output shaft (510).
3. Affix the fourth clutch bearing (511) onto the output shaft (510).
4. Rotate the transmission so that the oil pan flange faces downward.
Important: Be sure that the differential thrust washer (714) and the thrust bearing (715)
are either on the differential carrier assembly or in the case extension.
5. Remove the transmission case extension bolts (5). Remove the case extension assembly (6).
Important: During installation, do not push too hard, or damage could occur to the bushings
or the bearings.
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6. Hold the front differential carrier (700) in place and carefully install the output shaft (510)
into the transmission . Extend the shaft through the differential side gear.
7. Select a thrust washer (714) for the front differential carrier. The choice of washer will be
indicated by the final measurement of the drive end play procedure.
8. Affix the thrust washer (714) and the thrust bearing (715) onto the differential carrier (700).
9. Attach the case extension assembly (6) to the case (3) with four bolts (5).
Tighten
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Document ID: 39001
Page 1 of 1

1996 Buick Skylark
Drive Shaft Oil Seal Disassemble - Right Side

Tools Required
UseJ 23129 and J 6125-1B in order to remove the oil seal assembly (4) from the front wheel drive
shaft.
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Document ID: 39002
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1996 Buick Skylark
Drive Shaft Oil Seal Assemble - Right Side

Tools Required
J 29130 Axle Seal Installer
J 8092 Handle
Important: Inspect the seal assembly (4). Be sure that the seal was not damaged during
assembly. Check that the garter spring was not dislodged.
Use J 29130 and J 8092 in order to install the oil seal assembly (4) on the front wheel drive shaft.
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Document ID: 39004
Page 1 of 2

1996 Buick Skylark
Vehicle Speed Sensor Assemble
Important: Handle the vehicle speed sensor assembly carefully.

1. Inspect the vehicle speed sensor assembly (10) and the vehicle speed sensor O-ring seal
(11) for the following conditions:
Damaged connector
Cracked housing
Signs of rotor damage
Cuts or nicks on the O-ring seal
2. Install a new O-ring seal (11) on the vehicle speed sensor assembly (10).
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3. Install the vehicle speed sensor assembly (10) into the case extension.
4. Install the vehicle speed sensor bolt (9).
Tighten
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Document ID: 39005
Page 1 of 1

1996 Buick Skylark
Control Valve Body Clean
Important: Do not use solvent in order to clean the solenoid valves or the neoprene seals.
1. Clean the control valve body thoroughly in clean solvent.
Important: In the following steps, handle the parts carefully in order to avoid nicks and
scratches.
2. Move the valves with a pick or a small screwdriver in order to dislodge any dirt or debris.
3. Use an air nozzle in order to dry the control valve body and to blow out all of the passages.
4. Gently probe the small passages with a piece of identification tag wire or the equivalent.
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Document ID: 39006
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1996 Buick Skylark
Control Valve Body Inspection
1. Inspect the control valve body for the following:

A damaged or rough pump shaft bearing
Casting porosity
Interconnected oil passages
Damaged machined surfaces
Foreign material
2. Inspect the solenoids for the following:
Cut seals
Bent connectors or broken wires
Cracked or damaged plastic housings
Foreign material
3. Inspect the valves and bushings for the following:
Wear
Nicks
Scratches
4. Inspect the springs for damaged or distorted coils.
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Document ID: 39049
Page 1 of 7

1996 Buick Skylark
Control Valve Body Disassemble

Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs.
Personal injury could result.
Important: Position the control valve assembly on a clean surface before disassembly.
Important: All valves, springs, and bushings must be laid out on a clean surface in exactly the
same way in which the parts are removed. This will aid reassembly.
1. Remove the spring clip retainer (314) from the torque converter clutch (TCC) solenoid.
2. Remove the TCC solenoid valve (315) and seal (316).
3. Remove the converter clutch valve (335) and the spring (336).
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4. Remove the retainer (383) from the sleeve (384) of the TCC regulator valve (332).
5. Remove the sleeve (384), the TCC regulator valve (332), and the spring (331).
6. Remove the isolator valve (334) and the spring (333).
7. Remove the retainer (324) from the PWM solenoid valve assembly.
8. Remove the PWM solenoid valve assembly (325).
9. Remove the solenoid valve seals (326, 327).
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10. Remove the retaining pin (319) from the oil pump pressure relief valve.
11. Remove the bushing (320) from the oil pump pressure relief valve.
12. Remove the pressure relief valve (321), the valve seat (322), and the spring (323).
13.
14.
15.
16.
Remove
Remove
Remove
Remove
the
the
the
the
retainer (314) from the 1-2, 3-4 shift solenoid valve assembly (315).
1-2, 3-4 shift solenoid valve assembly (315) and the valve seal (316).
1-2 shift valve (318).
1-2 shift valve spring (317).
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17.
18.
19.
20.
21.
22.
23.
Page 4 of 7
Remove the retainer (302) from the line boost valve.

Remove the bore plug (303) from the line boost valve, the valve (304), and the spring (305).
Remove the retainer (306) from the pressure regulator.
Remove the reverse boost spring (307).
Remove the bushing retainer (308) from the reverse boost valve.
Remove the bushing (309) from the reverse boost valve.
Remove the reverse boost valve (310), the springs (311, 312), and the pressure regulator
valve (313).
24. Remove
valve.
25. Remove
26. Remove
valve.
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27. Remove
the coiled spring pin (363) and the valve spring (366) from the forward servo boost
the forward servo boost valve (367).
the coiled spring pin (363) and the valve spring (365) from the reverse servo boost
the bore plug (364) from the reverse servo boost valve.
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28. Remove the reverse servo boost valve (367).
29. Remove the retainer (314) from the 2-3 shift solenoid valve.
30. Remove the 2-3 shift solenoid valve assembly (315).
31. Remove the shift solenoid valve seal (316).
32.
33.
34.
35.
Remove
Remove
Remove
Remove
the
the
the
the
plug retainer (358) from the 4-3 manual downshift valve.

bore plug (359) from the 4-3 manual downshift valve.
4-3 manual downshift valve (360) and the spring (361).
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36.
37.
38.
39.
40.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
Page 6 of 7
bore plug retainer (353) from the 2-3 shift valve.

bore plug (354).
spring (355) from the 3-2 manual downshift valve.
3-2 manual downshift valve (356).
41.
42.
43.
44.
Remove the retainer (385) from the 1-2 accumulator valve bushing.
Remove the 1-2 accumulator valve bushing (349) and the 1-2 accumulator valve assembly.
Remove the plug retainer (338) from the 1-2 accumulator valve bushing.
Remove the plug (346), the valve (347), and the spring (348) from the 1-2 accumulator
valve bushing.
45. Remove the retainer (385) from the 3-4 accumulator valve bushing assembly.
46. Remove the 3-4 accumulator valve (350) and the spring (351) from the bushing.
47. Remove the 3-4 accumulator valve bushing (352).
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48. Remove the retainer (385) from the 1-2 accumulator valve bushing.
49. Remove the 1-2 accumulator valve bushing (342) and the 1-2 accumulator valve assembly.
50. Remove the plug retainer (338) from the 1-2 accumulator valve bushing.
Important: The position of the valve and the spring in the 1-2 accumulator assembly may
vary by model.
51. Remove the
bushing.
52. Remove the
53. Remove the
54. Remove the
plug (339), the 1-2 accumulator valve (341), and the spring (340) from the
retainer (385) from the 2-3 accumulator valve bushing assembly.
2-3 accumulator valve (343) and the spring (344) from the bushing.
2-3 accumulator valve bushing (345).
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Document ID: 39008
Page 1 of 6

1996 Buick Skylark
Control Valve Body Assemble
1.
2.
3.
4.
Insert the 2-3 accumulator valve bushing (345) into the valve body.
Insert the 2-3 accumulator valve (343) and the spring (344) into the valve body.
Install the bushing retainer (385).
Insert the 1-2 accumulator valve (341) and the spring (340) into the 1-2 accumulator
bushing (342).
5. Insert the 1-2 accumulator bushing plug (339) and the plug retainer (338) into the 1-2
accumulator bushing (342).
6. Insert the 1-2 accumulator valve assembly into the valve body.
7. Install the 1-2 accumulator bushing retainer (385).
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8.
9.
10.
11.
Insert the 3-4 accumulator valve bushing (352) into the valve body.
Insert the 3-4 accumulator valve (350) and the spring (351) into the valve body.
Install the bushing retainer (385).
Install the 1-2 accumulator valve (347) and the spring (348) into the 1-2 accumulator
bushing (349).
12. Insert the 1-2 accumulator bushing plug (346) and the plug retainer (338) into the 1-2
accumulator bushing (349).
13. Insert the 1-2 accumulator valve assembly into the valve body.
14. Install the 1-2 accumulator bushing retainer (385).
15.
16.
17.
18.
Install the 2-3 shift valve (357) into the valve body.
Assemble the 3-2 manual downshift valve (356) and the spring (355).
Insert the bore plug (354) into the valve body.
Install the bore plug retainer (353).
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19.
20.
21.
22.
Page 3 of 6
Install the 3-4 shift valve (362) into the valve body.
Assemble the 4-3 manual downshift valve (360) and the spring (361).
Insert the bore plug (359) into the valve body.
Install the bore plug retainer (358).
23. Insert a new seal (316) onto the 2-3 shift solenoid valve (315).
24. Install the 2-3 shift solenoid valve (315) into the valve body.
25. Install the solenoid valve retainer (314).
26. Assemble the reverse boost valve (367) and the spring (365).
27. Install the boost valve bore plug (364).
28. Install the coiled spring pin (363).
29. Assemble the forward servo boost valve (367) and the valve spring (366).
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30. Install the forward boost valve retainer pin (363).
31. Install the reverse boost valve (310), the springs (311, 312), and the pressure regulator
valve (313) into the valve body.
32. Assemble the reverse boost valve bushing (309) and the retainer (308).
33. Insert the reverse boost spring (307) into the valve body.
34. Insert the pressure regulator retainer (306).
35. Install the spring (305), the line boost valve (304), and the bore plug (303) into the valve
body.
36. Install the line boost valve retainer (302).
37.
38.
39.
40.
Install the valve spring (317) and the 1-2 shift valve (318) into the 1-2 shift valve body.
Insert the seal (316) onto the 1-2 shift solenoid valve (315).
Insert the shift solenoid valve (315) into the valve body.
Install the shift solenoid valve retainer (314).
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41. Insert the valve spring (323), the valve seat (322), and the valve (321) into the oil pump
pressure relief valve body.
42. Insert the pressure relief bushing (320) into the valve body.
43. Install the bushing retaining pin (319)
44. Affix new seals (326, 327) onto the PWM solenoid valve assembly (325).
45. Insert the solenoid valve (325) into the valve body.
46. Install the retainer (324) into the PWM solenoid valve assembly.
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Page 6 of 6
47. Insert the isolator spring (333) and the valve (334) into the valve body.
48. Insert the torque converter clutch (TCC) regulator valve (332) and the spring (331) into the
valve sleeve (384).
49. Insert the valve sleeve assembly into the valve body.
50. Insert the TCC regulator valve retainer (383).
51.
52.
53.
54.
Insert the TCC valve spring (336) and the valve (335) into the valve body.
Install a new seal (316) onto the TCC solenoid valve (315).
Insert the solenoid valve (315) into the valve body.
Install the solenoid valve retainer (314).
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10/14/2010
Document ID: 39009
Page 1 of 1

1996 Buick Skylark
Oil Pump Shaft Bearing Disassemble

Tools Required
J 28698 Pump Bearing Remover
J 7079-2 Driver Handle
1. Use J 28698 andJ 7079-2 in order to push the pump shaft bearing (368) partially out of the
valve body.
2. Use a screwdriver in order to complete the removal of the pump shaft bearing.
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10/14/2010
Document ID: 39010
Page 1 of 1

1996 Buick Skylark
Oil Pump Shaft Bearing Assemble

Tools Required
J 35914 Pump Bearing Remover/Installer
J 7079-2 Driver Handle
Use J 35914 , J 7079-2 , and a hammer. Gently tap the pump shaft bearing (368) into the valve
body.
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10/14/2010
Document ID: 39011
Page 1 of 1

1996 Buick Skylark
Oil Pump Drive Shaft Assemble
1. Inspect the oil pump drive shaft (227) for the following:
A scored or rough journal surface
Stripped or burred splines
A cut or damaged seal
2. Install a new seal (228) onto the oil pump drive shaft (227).
3. Install the oil pump drive shaft assembly (227) into the channel plate (400).
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10/14/2010
Document ID: 39012
Page 1 of 5

1996 Buick Skylark
Control Valve Body and Spacer Plate Assemble

Tools Required
J 25025 Guide Pins
1. Inspect the spacer plate (370) from the control valve body for the following:
Bent or stuck thermal elements
Plugged holes
Damage from being bent
Plugged or damaged solenoid screens
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Document ID: 39012
Page 2 of 5
2. Inspect each check valve seat (370) for excessive peening. Place a ball check valve (372) on
each seat and use a flashlight in order to look for visible light between the valve and the
seat.
3. Place the ball check valves (372) into the valve seats in the case cover.
4. Use J 36850 or equivalent in order to hold the valves in position.
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Document ID: 39012
Page 3 of 5
5. Insert the solenoid screens (374) into the valve body spacer plate (370).
6. Insert the TCC orifice screen (382) into the valve body spacer plate (370).
7. Assemble the valve body spacer plate and two spacer plate gaskets (369, 371) onto the
channel plate (400).
8. Position the check ball valves (372, 373) onto the valve body assembly. Retain the valves
with J 36850 or equivalent.
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Document ID: 39012
Page 4 of 5
Important: Be sure that the check ball valves do not fall out of the valve body assembly
during installation.
9. Install the control valve body alignment sleeve (410) into the case cover (400).
10. Install the control valve assembly (300) onto the case cover and the guide pins (410).
11. Install the retaining bolts (375-380) into the valve body at the locations indicated.
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Document ID: 39012
Page 5 of 5
Important: Tighten and torque the bolts in a spiral pattern starting from the center. If the
bolts are torqued at random, valve bores may become distorted and inhibit proper valve
operation.
12. Tighten the valve body assembly bolts.
Tighten
Tighten bolts 380, 379, 375 to 25 Nm (18 lb ft).
Tighten bolts 376, 378 to 12 Nm (106 lb in).
Tighten bolts 377 to 12 Nm (106 lb in).
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Document ID: 39013
Page 1 of 1

1996 Buick Skylark
Transmission Fluid Pump Disassemble
Important: The automatic transmission oil pump assembly has a pump slide, seal, vanes,
and a rotor that are factory selected for size. Do not switch parts with another pump.
1.
2.
3.
4.
Remove
Remove
Remove
Remove
the
the
the
the
oil pump cover bolts (205).

oil pump cover (201).
pump rotor (210), the vane rings (209) and the bushing (208).
vanes (211), the oil seal ring (212), and the slide seal (213).
Caution: Valve springs can be tightly compressed. Use care when removing retainers and
plugs. Personal injury could result.
5.
6.
7.
8.
Remove
Remove
Remove
Remove
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the
the
the
the
outer and the inner oil pump prime springs (222, 223).
pump slide seal (220) and the slide seal support (221).
pump slide pivot pin (215).
oil screen assembly (219).
10/14/2010
Document ID: 39015
Page 1 of 6

1996 Buick Skylark
Transmission Fluid Pump Assemble
1. Inspect the oil pump for the following:

A worn, scored, or gouged pump slide (214)
Cracks, wear, or damage to the rotor (210), or the vanes (211)
Cuts or damage to the seals (212, 213)
Broken priming springs (222, 223)
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Document ID: 39015
Page 2 of 6
2. Inspect the oil pump body (202) for the following:

Porosity
A worn, scored, or damaged pump pocket
Interconnected oil passages
Damaged machine surfaces
3. Inspect the pressure screen assembly (219) for damage or debris.
4. Inspect the oil pump cover (201) for cracks, wear, or gouges from the pump vanes.
5. Inspect the bushing (208) for wear, scoring, and scratches.
Important: Laser marks on the oil pump body indicate the size of the selective parts which
were used in assembly. If these correct parts are not selected for replacement, damage to
the oil pump and to the transmission will occur.
6. Measure the pump rotor (210).
7. Select the proper replacement size. Refer to the Rotor Selection table found in Oil Pump
Specifications .
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Page 3 of 6
8. Measure the oil pump vanes (211).

9. Select the proper replacement size. Refer to the Vane Selection table found in Oil Pump
Specifications .
10. Measure the oil pump slide (214).

11. Select the proper replacement size. Refer to the Slide Selection table found in Oil Pump
Specifications .
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10/14/2010
Document ID: 39015
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page 4 of 6
Insert the oil pump screen (219).

Insert the pump slide seal (221) and the support (220) into the slot on the slide (214).
Insert the pump slide (214) and the pivot pin (215) into the pump body (202).
Install the inner and the outer priming springs (222, 223) as an assembly into the pump
body (202).
Install the first vane ring (209).
Insert the oil seal (213) and the oil seal ring (212) into the slide.
Insert the rotor (210) into the pump body (202).
Assemble the pump vanes (211) into the rotor (210). The vanes must be flush with the top
of the rotor.
Install the second vane ring (209).
21. Insert the pump cover (201) and the bolt (205).
Tighten
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Document ID: 39015
Page 5 of 6
22. Install the transmission oil pump assembly (300) onto the control valve assembly.
23. Install the 11 oil pump bolts as indicated (204, 206, 207)
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Document ID: 39015
Page 6 of 6
24. Tighten the bolts (204, 205, 206, 207).

Tighten
Tighten the bolts (204, 207) to 12 Nm (106 lb in).
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10/14/2010
Document ID: 39016
Page 1 of 2

1996 Buick Skylark
Wiring Harness Assemble
1. Inspect the transmission wiring harness assembly (224) for the following:
Cut or pinched wires
Cut wire insulation
Bent or broken electrical connectors
2. Position the wire harness assembly (224) onto the valve body and pump assembly.
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General Motors
Corporation.
3. Mate each connector
to2010
its respective
electrical
component.
Engage the locking tabs.
10/14/2010
Document ID: 39016
Page 2 of 2
4. Secure the harness conduit into the retaining clips (225, 226).
5. Insert the automatic transmission temperature sensor (391) into the retaining clip (390).
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10/14/2010
Document ID: 39017
Page 1 of 4

1996 Buick Skylark
Control Valve Body and Gasket Assemble
Important: Some models are assembled with stamped steel control valve body covers.
Some models are assembled with cast aluminum covers that have machined surfaces and
threaded bolt holes. Refer to the following procedures accordingly.
1. Inspect the control valve body cover for the following:
Stamped steel
Dents to the gasket sealing surfaces
Dents anywhere that may cause interference during assembly
Flatness of the gasket sealing surfaces
2. Inspect the valve body cover gaskets for nicks or other damage.
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Document ID: 39017
Page 2 of 4
3. Inspect the control valve body cover for the following:
Cast aluminum
Cracks, nicks, or other damage to the gasket seal surfaces
Bolt holes for damaged or stripped threads
Cracks or porosity in the casting
4. Inspect the valve body cover gaskets for nicks or other damage. With the aluminum valve
body covers, you may reuse any non-damaged gaskets.
Important: Do not use bolts with inverted conical washers when you assemble the stamped
steel control valve body cover.
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Document ID: 39017
Page 3 of 4
5. Inspect the bolts (52) for inverted washers.
6. Affix the cover gasket onto the transmission case assembly:
Stamped steel side cover

Affix the steel cover inner cover gasket onto the case cover.
Position the steel cover onto the case.
Finger start the bolts and nuts.
Tighten
Tighten
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Document ID: 39017
Page 4 of 4
7. Affix the cover gasket onto the transmission case assembly:
Cast aluminum side cover

Affix the inner valve body cover gasket onto the case cover.
Position the aluminum cover onto the case.
Finger start the bolts in the positions shown.
Tighten
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Document ID: 39019
Page 1 of 2

1996 Buick Skylark
Thermo Element Adjustment

Tools Required
J 34094-A Thermal Element Height Gauge
1. Remove the thermo element plate pins (120).

2. Remove the thermo element (121) and the thermo element plate (122).
3. Use J 34094-A in order to set the height of the thermo element plate center pin (123).
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Document ID: 39019
Page 2 of 2
4. Install the thermo element plate (122).

5. Use J 34094-A in order to set the height of the thermo element plate pin (120) that is
farthest from the accumulators.
6. Use J 34094-A in order to set the height of the second thermo element plate pin (120).
7. Carefully install the thermo element (121) between the two thermo element plate pins (120).
8. The V in the thermo element (121) must contact the thermo element plate (123).
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10/14/2010
Document ID: 39023
Page 1 of 1

1996 Buick Skylark
2-1 Manual Band Servo Disassemble
1. Remove the servo piston cylinder (114) from the servo cover (104).
2. Remove the O-ring seal (113) from the servo piston cylinder (114).
3. Remove the servo piston assembly (106-111), the servo piston spring (112) and the servo
exhaust screen (115) from the servo piston cylinder (114).
4. Remove the servo piston seal (107) from the servo piston (108).
5. Use a small screwdriver in order to remove the servo piston pin retaining ring (106) from the
servo piston pin (111).
6. Remove the servo piston (108), the servo piston cushion spring (109) and the servo piston
spring retainer (110) from the servo piston pin (111).
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Document ID: 39024
Page 1 of 2

1996 Buick Skylark
2-1 Manual Band Servo Assemble
1. Inspect the components of the 2-1 manual band servo for the following conditions:
A damaged, worn or porous servo piston cylinder (114)
A damaged, worn or porous servo piston (108)
A damaged or worn servo piston pin (111)
A broken or damaged servo piston spring (112)
A broken or damaged servo piston cushion spring (109)
A damaged or plugged servo exhaust screen (115)
A damaged servo cover seal (105)
A damaged servo piston seal (107)
A damaged servo piston cylinder O-ring seal (113)
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Document ID: 39024
Page 2 of 2
2. Assemble the servo piston spring retainer (110), the servo piston cushion spring (109) and
the servo piston (108) onto the servo piston pin (111).
3. Use a small screwdriver in order to install the servo piston pin retaining ring (106).
4. Install the servo piston seal (107) onto the servo piston (108). Lubricate the servo piston
seal (107) with automatic transmission fluid.
5. Assemble the servo exhaust screen (115) and the servo piston cylinder O-ring seal (113)
onto the servo piston cylinder (114). Lubricate the servo piston cylinder O-ring seal (113)
with automatic transmission fluid.
6. Attach the servo piston spring (112) to the servo piston assembly (106-111).
7. Install the servo piston and spring assembly (106-112) into the servo piston cylinder
assembly (113-115) and set the assemblies aside.
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Page 1 of 2

1996 Buick Skylark
Accumulator Components Disassemble
1. Remove the seven remaining accumulator cover bolts (131) from the accumulator assembly.
2. Remove the accumulator cover (132), the spacer plate (134), and the gaskets (133) from
the accumulator housing assembly (140).
3. Remove the 1-2 and 2-3 accumulator pistons (136), the piston pins (135), and the inner and
outer springs (138, 139) from the accumulator housing (140). The springs and the pistons
vary by model.
4. Remove the piston oil seal rings (137) from the 1-2 and 2-3 accumulator pistons (134).
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5. Disassemble the manual
2-1General
band Motors
servo.Corporation.
Remove the
forward
band servo oil pipes (124,
All rights
reserved.
2010
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Document ID: 39026
Page 2 of 2
125), and remove the lube oil pipe assembly (126) from both the accumulator cover (132)
and from the manual 2-1 band servo cover (104).
The lube oil pipe (126)
The hose clamps (127)
The hose (128)
The lube oil pipe retainer (129)
The lube oil pipe and the washer (130)
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Document ID: 39027
Page 1 of 5

1996 Buick Skylark
Accumulator Components Assemble
1. Inspect the accumulator housing (140), the spacer plate (134), the gaskets (133), and the
cover (132) for the following conditions:
A damaged lube, and servo oil pipe holes in the accumulator cover.
A damaged, improperly machined, or porous accumulator cover
A bent or damaged accumulator spacer plate
Damaged accumulator cover gaskets
Stripped or damaged bolt holes in the accumulator housing
A damaged, worn, improperly machined, or porous accumulator housing
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Document ID: 39027
Page 2 of 5
2. Inspect the accumulator pistons (136), the springs (138, 139), the seals (137), and the pins
(135) for the following conditions:
Broken or collapsed piston springs (inner and outer)
Broken or collapsed piston cushion springs
Bent or worn accumulator piston pins
Damaged, worn, or porous accumulator pistons
Damaged accumulator piston seals
3. Inspect the servo and lube oil pipe components (124-130) and the manual 2-1 band servo
cover (104) for the following conditions:
A damaged lube, and servo oil pipe holes in the servo cover
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Document ID: 39027
Page 3 of 5
A damaged, improperly machines, or porous servo cover

Bent, plugged, or damaged lube and servo oil pipes
A plugged or damaged lube oil hose
Damaged hose clamps
A damaged lube oil pipe retainer
A missing lube oil pipe washer
4. Install the oil seal ring (137) onto the 2-3 accumulator piston (136). Lubricate the oil seal
ring with automatic transmission fluid.
5. Assemble the piston pin (135) and the 2-3 accumulator piston (136).
6. Insert the inner and outer springs (138) for the 2-3 accumulator piston, and the piston
assembly (136) into the accumulator housing (140). The springs may vary by model.
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Document ID: 39027
Page 4 of 5
7. Install the oil seal ring (137) onto the 1-2 accumulator piston (136). The piston may vary by
model. Lubricate the oil seal ring with automatic transmission fluid.
8. Assemble the piston pin (135) and 1-2 accumulator piston (136).
9. Insert the inner and outer springs (139) for the 1-2 accumulator piston, and the piston
assembly (136) into the accumulator housing (140). The springs and the pistons and the
order of installation may vary by model.
10. Install the accumulator spacer plates (134), the gaskets (133), and the cover (132) onto the
accumulator housing (140).
11. Install seven accumulator cover bolts (131).
Tighten
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Document ID: 39027
Page 5 of 5
12. Assemble the following parts:

The lube oil pipe (126)
The hose (128)
The hose clamps (127)
The pipe retainer (126)
The pipe with the washer (130)
13. Install the manual 2-1 band servo and the forward band servo oil pipes (124, 125) into the
accumulator assembly (132-140).
14. Install the manual 2-1 band servo and the forward band servo oil pipes (124, 125) into the
manual 2-1 band servo cover (104).
15. Install the lube oil pipe assembly (126) into the accumulator assembly (132-140).
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Document ID: 39029
Page 1 of 2

1996 Buick Skylark
Accumulator Assembly, 2-1 Band Servo Assemble
1. Install the 2-1 manual band servo cover seal (105) into the case. Lubricate the 2-1 manual
band servo cover seal (105) with automatic transmission fluid.
Notice: Do not damage the 2-1 manual band servo exhaust screen on installation.
2. Install the 2-1 manual band servo assembly (106-116) into the case. Make sure that the 2-1
manual band servo pin engages the 2-1 manual band assembly.
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Document ID: 39029
Page 2 of 2
3. Install the accumulator (132-140) and 2-1 manual band servo cover assembly (104) into the
case.
4. Install the lube oil pipe and washer assembly (130) through the case and into the lube hole
in the differential carrier internal gear.
5. Use a screwdriver in order to lock the lube oil pipe retainer (129) into the case.
6. Install the three 2-1 manual band servo cover bolts (103).
Tighten
7. Install the four accumulator cover bolts (131).
Tighten
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10/14/2010
Document ID: 39030
Page 1 of 3

1996 Buick Skylark
Transmission Fluid Pan and Filter Assemble
1. Inspect the oil pan (24) for the following conditions:

A damaged sealing surface
A dented or cracked bottom surface
2. Inspect the oil pan gasket (25) for the following conditions:
A bent or damaged seal core
A damaged rubber seal surface
A damaged gasket
3. Inspect the oil pan magnet (26) for damage or misalignment
4. Clean the oil pan (24), the oil pan gasket (25) and the oil pan magnet (26) in order to
remove any sediment.
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Document ID: 39030
Page 2 of 3
5. Position the transmission so that the oil pan sealing surface is facing upward.
6. Lubricate the oil filter seal assembly (101) with transmission fluid.
7. Using a socket and a plastic mallet, gently tap the oil filter seal assembly (101) into the
case (3).
8. Install the oil filter assembly (100) into the case (3).
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Page 3 of 3
9. Install the oil pan gasket (25) onto the case (3). The old gasket is reusable if the gasket is
not damaged.
10. Install the oil pan (24) onto the case (3).
11. Install the 20 oil pan bolts (23).
Tighten
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10/14/2010
Document ID: 39032
Page 1 of 1

1996 Buick Skylark
Forward Band Servo Components Disassemble
1.
2.
3.
4.
Remove the servo piston spring (22) from the servo assembly.
Remove the oil seal ring (18) from the servo piston (16).
Use a small screwdriver in order to remove the snap ring (15) from the servo piston pin (21).
Remove the servo piston (16), the servo piston cushion spring (19), the cushion spring
retainer (17), and the servo piston pin (21).
5. If the cushion spring retainer (17) is damaged, remove the retainer from the servo piston.
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10/14/2010
Document ID: 39033
Page 1 of 3

1996 Buick Skylark
Forward Band Servo Assemble
1. Inspect the forward band servo components for the following conditions:
A damaged, worn, or porous servo piston
A damaged servo piston seal
A damaged, worn, or porous servo cover
A damaged servo cover seal
A broken or collapsed servo piston spring
A broken or collapsed servo piston cushion spring
A damaged or worn servo piston pin
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10/14/2010
Document ID: 39033
Page 2 of 3
2. Install the servo piston cushion spring retainer (17) into the servo piston, if necessary.
3. Assemble the servo piston (16), the servo piston cushion spring (19), the cushion spring
4. Install the servo pin snap ring (15) into the servo piston pin (21).
5. Install the servo piston oil seal ring (18) into the servo piston (16).
6. Install the servo piston spring (22) into the servo assembly.
7. Position the transmission so that the oil pan is facing up.

8. Affix the servo cover seal (14) onto the servo cover (13).
9. Install the servo assembly (13-22) into the servo cover. Pivot the servo into the cover in
order to prevent the piston seal from being damaged.
10. Install the servo and the cover assembly (13-22) into the case (3).
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Document ID: 39033
Page 3 of 3
11. Using a long screwdriver, pry against the work bench in order to compress the forward band
servo assembly (13).
13. Install the three forward band servo cover bolts (12).
Tighten
14. Remove the long screwdriver.
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10/14/2010
Document ID: 39035
Page 1 of 1

1996 Buick Skylark
Reverse Band Servo Components Disassemble
1.
2.
3.
4.
Remove the reverse band servo piston spring (49) from the servo piston assembly (44).
Remove the oil seal ring (43) from the servo piston (44).
Use a small screwdriver in order to remove the snap ring (42) from the servo piston pin (48).
Remove the servo piston (44), the servo piston cushion spring (45), the servo piston retainer
(46), and the servo piston pin (48).
5. If the servo piston cushion spring retainer (17) is damaged, remove the retainer from the
servo piston (44).
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10/14/2010
Document ID: 39036
Page 1 of 3

1996 Buick Skylark
Reverse Band Servo Assemble
1. Inspect the reverse band servo components for the following conditions:
A damaged, worn, or porous servo piston (44)
A damaged, worn, or porous servo cover (40)
A damaged servo piston seal (43)
A damaged servo cover seal (41)
A damaged servo cover snap ring (39)
A broken or collapsed servo piston spring (49)
A broken or collapsed servo piston cushion spring (45)
A damaged or worn servo piston pin (48)
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Document ID: 39036
Page 2 of 3
2. Install the cushion spring retainer (17) into the servo piston (44), if necessary.
3. Assemble the servo piston (44), the servo piston cushion spring (45), the servo piston
4. Install the servo pin snap ring (42) into the servo piston pin (48).
5. Install the oil seal ring (43) into the servo piston (44).
6. Assemble the piston spring (49) into the servo assembly (43-48).

8. Affix the seal (41) onto the servo cover (40).
9. Install the servo and the cover assembly into the case (3).
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10/14/2010
Document ID: 39036
Page 3 of 3
10. Using a long screwdriver, pry against the work bench in order to compress the reverse band
servo assembly.
12. Use a small screwdriver in order to install the reverse band servo cover snap ring (39).
13. Remove the long screwdriver.
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10/14/2010
Document ID: 39038
Page 1 of 2

1996 Buick Skylark
Vacuum Modulator Inspection

Tools Required
J 23738-A Hand Vacuum Pump (or equivalent)
J 36619 Modulator Checking Tool
1. Inspect the modulator components for the follow conditions:

A damaged modulator valve (34)
A damaged modulator assembly (32)
A damaged modulator O-ring seal (33)
A damaged modulator retainer (31)
2. Install J 23738-A or equivalent onto the vacuum pipe nipple of the modulator assembly.
3. Apply 15 kPa of vacuum to the modulator assembly (32) under the following criteria:
Hold the vacuum for 30 seconds
Confirm that the plunger retracts into the modulator assembly
4. Remove J 23738-A from the modulator assembly.
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10/14/2010
Document ID: 39038
5.
6.
7.
8.
Page 2 of 2
Use a modulator assembly that is known to be good.

Install J 36619 between the good modulator and the modulator to be checked.
Push the modulators towards each other.
Note the indicator on J 36619 :
If the indicator line (1) is visible, the modulator is OK
If the indicator line moves out of view, replace the modulator
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Document ID: 39042
Page 1 of 2

1996 Buick Skylark
Vacuum Modulator and Valve Assemble

Tools Required
1. Use a small magnet tool in order to install the modulator valve (34) into the case.
2. Apply J 36850 or equivalent to a new modulator O-ring seal (33).

3.
Install the new O-ring seal (33) onto the modulator assembly (32).
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Document ID: 39042
Page 2 of 2
4. Install the modulator assembly (32) into the case (3).

5. Install the modulator retainer (31).
6. Install the modulator retainer bolt (30).
Tighten
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10/14/2010
Document ID: 39044
Page 1 of 1

1996 Buick Skylark
Transmission Holding Fixture Disassemble

Tools Required
J 28664-B Transmission Holding Fixture
J 3289-20 Holding Fixture Base
1. Remove the pin from J 3289-20 .

2. Remove the transmission and J 28664-B from J 3289-20 .
3. Remove J 28664-B from the transmission.
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10/14/2010
Document ID: 39045
Page 1 of 2

1996 Buick Skylark
Torque Converter Inspection

Tools Required
J 26900-13 Magnetic Indicator Base
J 35138 Torque Converter End Play Checking Tool
1.
2.
3.
4.
Position the torque converter (1) on the bench with the flywheel lugs facing down.
Install J 26900-13 , J 35138 , and J 8001 onto the torque converter (1).
Set the dial indicator to 0.
Lift J 35138 and note the dial indicator reading:
The torque converter end play should be 0.5 mm (0.020 in) or less
If the end play is too high, replace the torque converter (1)
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10/14/2010
Document ID: 39045
Page 2 of 2
5. Inspect and replace the torque converter (1) for the following conditions:
Overheated (torque converter will be blue in color)
Leaking at the weld areas
A damaged torque converter pilot
Evidence of metal particles in the converter, the oil cooler, or the cooler pipes
A damaged torque converter stator, a damaged pump, or a damaged turbine
A damaged or worn torque converter bushing (2)
Contaminated automatic transmission fluid due to engine coolant
6. Inspect the torque converter for stripped bolt hole threads. If found, repair the torque
converter.
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Document ID: 39046
Page 1 of 2

1996 Buick Skylark
Torque Converter Assemble

Tools Required
1. Apply J 36850 or equivalent to a new turbine shaft O-ring seal (520).

2. Apply J 36850 or equivalent to the turbine shaft splines (518).
3. Affix the turbine shaft O-ring seal (520) onto the turbine shaft (518).
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Document ID: 39046
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Caution: The torque converter weighs approximately 65 lbs. Personal injury may result if
you lift the torque converter improperly.
4. Install the torque converter assembly (1).
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10/14/2010
Document ID: 300029
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories | Roof |

Specification
Application
Metric
English
Sunroof Glass Retaining Screws
3 Nm
27 lb in
Sunroof Motor Actuator
3 Nm
27 lb in
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2/7/2011
Document ID: 346513
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Sunroof Schematics
Cell 122
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Document ID: 346525
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Power Roof Systems Component Views

Passenger Compartment, In the Center of the Headliner
(1) Sunroof Control Module

(2) C221
(3) Sunroof Actuator
(1) G301
(2) Inflatable Restraint Sensing And Diagnostic Module
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Document ID: 403935
Page 1 of 2
Power Roof Systems Connector End Views

Table 1:
Sunroof Control Module C1
Table 2:
Table 3:
Sunroof Switch
12052856
Pin
Wire Color
Circuit No.
Function
GRN
127
Motor Control - Open
BLU
129
Motor Control - Closed
BRN
341
Fused Output - IGN
BLK
1450
Ground
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Document ID: 403935
Page 2 of 2
30-39-1080
8 Way F
Pin
Wire Color
Circuit No.
YEL
133
2-4
--
--
WHT
128
Sunroof Switch Return
BRN
100
Sunroof Switch Signal - Open
ORN
110
Sunroof Switch Signal - Closed
RED
132
Sunroof Limit Switch Signal
Function
Sunroof Limit Switch Closed Signal
Not Used
Sunroof Switch
12064860
Pin
Wire Color
Circuit No.
A-B
--
--
ORN
110
Sunroof Switch Close Input
WHT
128
Sunroof Return
BRN
100
Sunroof Switch Open Input
--
--
Function
Not Used
Not Used
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2/7/2011
Document ID: 449958
Page 1 of 2
Sunroof Switch Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
5.
Using a flat-bladed tool, gently pry the front courtesy / reading lamp tabs inward.
Remove the overhead console.
Remove the fasteners (1) securing the power sunroof switch to the overhead console.
Remove the power sunroof switch.
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Document ID: 449958
1.
2.
3.
4.
Page 2 of 2
Install the power sunroof switch into the overhead console.

Install the fasteners (1) to secure the power sunroof switch.
Install the overhead console into the headliner opening.
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Document ID: 470241
Page 1 of 2
Sunroof Switch Replacement (Pontiac With CF5)

Removal Procedure
1. Using a flat-bladed tool (1), gently pry the sunroof switch (2) from the headliner.
3. Remove the sunroof switch (2).
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Document ID: 470241
Page 2 of 2
1. Connect the electrical connector to the sunroof switch (2).

2. Gently press the sunroof switch (2) into the headliner assembly.
The locking tabs on the switch secure the switch to the headliner assembly.
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Document ID: 398987
Page 1 of 4
Sunroof Replacement
Removal Procedure
1. Lower the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
2. Cycle the glass panel to the rear.
Important: Do not remove the fine-thread machine fasteners (4) second from the rear.
Identify the fasteners from the inside of the vehicle.
3. Remove the 8 fasteners (2) from the cover plates. Start with the rear most fastener on both
sides.
4. Cycle the glass panel to the flush or closed position.
5. Remove the motor. Refer to Power Sunroof Motor Replacement .
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Document ID: 398987
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6. Remove the 2 transmission fasteners (1) at the rear of the sunroof housing.
Important:
To prevent damage to the finish, mask the roof panel in front of the sunroof opening
using masking tape and paper.
Handle the module by the glass panel. Do not squeeze the module or bend the
components.
7. Remove the sunroof module (1) by lifting up and forward.
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Document ID: 398987
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1. Insert the rear of the module through the roof opening. Index the module on the raised
guides on the track.
2. Slide the module (1) into the sunroof opening. Do not damage the finish at the front of the
opening.
As you slide the module under the rear retaining clips, you will feel resistance during the last
6-9 cm (2-3 in) of travel.
3. Verify that the module (1) is under the clips. This will prevent noise during travel over road
irregularities.
4. Lower the glass panel into the opening.
5. Install the 2 fasteners (1) in the transmission.
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Document ID: 398987
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6. Install the motor. Refer to Power Sunroof Motor Replacement .

7. Cycle the glass fully to the rear.
8. Cycle the glass forward 3 mm (0.125 in) in order to remove the load from the bumpers.
9. Install the 2 rear fasteners (one per side) in the module (3) in order to align the unit.
10. Install the 6 fasteners (2).
11. Inspect for the following conditions:
Proper operation
Proper fit
Synchronization
12. Install the headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
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Document ID: 307697
Page 1 of 2
Sunroof Panel Vertical Adjustment

In order to provide the proper sealing and minimize the windnoise, adjust the height of the sliding
glass panel in the following manner:
Equal in height from side-to-side

Front of the sliding glass panel (1), flush to 1.0 mm (0.040 in) below the roof panel (2)
Rear of the sliding glass panel, flush to 1.0 mm (0.040 in) above the roof panel
With the sliding glass panel in the closed position, inspect the height of the glass panel at the
following locations:
The front of the glass panel
The rear of the glass panel
If the panel height is not within the above specifications, perform the following adjustment
procedure:
Important: Adjust the sliding glass panel height one corner at a time. Only adjust the
corners that are not at the proper height. After adjusting each corner, inspect the height of
the entire sliding glass panel in order to determine if additional adjustment is required.
1. With the glass panel fully closed, slide the sunshade fully rearward.
2. Remove the 3 fasteners from the front edge of the shield ring. Slide the shield ring rearward.
Important: DO NOT loosen all 3 of the fasteners on the side being adjusted.
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Document ID: 307697
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3. In order to adjust any corner, complete the following steps:

3.1. Loosen the glass panel mounting fastener nearest to the corner being adjusted.
3.2. Loosen the center mounting fastener on the side being adjusted.
4. After loosening the 2 fasteners, move the glass panel up or down by hand.
Tighten
Tighten the 2 fasteners to 3 Nm (27 lb in).
5. Inspect the sliding glass panel height.
Readjust the height as needed.
6. Repeat the adjustment procedures on the other corners as needed in order to meet the
height specifications.
7. Slide the shield ring forward.
8. Install the 3 retaining fasteners.
Tighten
Tighten the 3 fasteners to 3 Nm (27 lb in).
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Document ID: 307699
Page 1 of 2
Sunroof Panel Horizontal Adjustment

Ensure that the glass panel weatherstrip seal has contact with the metal roof panel around the
entire periphery of the seal when the sliding glass panel is in the closed position. Ensure that the
weatherstrip is not crushed at either of the following locations:
The front of the panel
The rear of the panel
Inspect for contact of the seal with the metal roof panel around the periphery of the seal. Insert
one of the following components between the seal and the metal roof panel:
A business card
A 0.381 mm (0.015 in) feeler gage
Drag the card or gage around the entire seal contact area.
Ensure that the business card or the feeler gage is making continuous contact between the seal
and the metal roof panel around the entire seal contact area. If the gap is excessive at the front or
rear of the panel, adjust the sliding glass panel in the fore/aft position.
1. Fully open the sliding glass panel.

2. Working from the top of the vehicle, note the position of the track assembly on the fore/aft
adjustment scale.
3. Loosen the track cover rail fasteners (2) on both sides of the sunroof module.
4. For fore/aft adjustment, loosen only those fasteners called out in the graphic.
5. Slide the track cover rail on both sides forward or rearward as needed 1 or 2 notches on the
adjustment scale (4).
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Tighten the fasteners.

Ensure that the following items are positioned evenly fore/aft:
The left tracks
The right tracks
6. Close the sliding glass panel.
7. Inspect the seal position again using a business card or feeler gage.
8. Repeat the adjustment procedure as needed in order to achieve the correct seal contact.
Ensure that all of the fasteners are tight after the adjustment procedure.
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2/7/2011
Document ID: 398978
Page 1 of 3
Track and Motor Synchronization

When the sliding glass panel is in the closed position, verify that the following conditions exist:
The glass panel is centered in the roof panel opening.
The lifter arms firmly hold the glass panel in position.
1. Completely or partially open the sunroof.
2. Close the sunroof. Use the switch until the motor stops.
3. Verify that the following conditions exist:
The sliding glass panel and the motor are in the closed position.
The sliding glass panel is approximately even with the roof panel.
The sliding glass panel is level and centered in the roof opening.
4. Adjust the motor synchronization if the following conditions exist:
The rear of the panel is noticeably low or high in the rear.
The rear of the panel is loose and may be moved up and down using your hand.
5. If the following conditions do not exist, refer to Sunroof Panel Vertical Adjustment and
Sunroof Panel Horizontal Adjustment :
The glass panel is centered approximately in the opening.
The glass panel is even with the roof panel.
The glass panel is not loose at the rear.
6. Lower the rear of the headliner in order to access sunroof motor. Refer to Headlining Trim
Panel Replacement in Interior Trim.
Important: Do not disconnect the electrical connection.

7. Remove the sunroof motor from the mounting.
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Document ID: 398978
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8. With the motor removed from the mounting and the ignition in the ON position, move the
sunroof switch to the rear position for several seconds.
Release the switch.
9. Push the switch into the forward position.
Hold the switch until the motor stops.
Important: Do not move the sunroof switch until after the motor is installed.
10.
11.
12.
13.
Turn the ignition to the OFF position.

Slide the sunshade fully rearward.
Remove the 3 fasteners from the front edge of the shield ring.
Slide the shield ring rearward.
14. Locate the sunroof track transmission drive gear (1).
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Document ID: 398978
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15. Turn the sunroof track transmission drive gear clockwise or counterclockwise as needed in
order to align the lifter guide pin (2) with the fourth rib (1) from the rear of the lifter arm.
16. Verify that the following conditions exist:
The lifter arms hold the rear of the glass panel tightly in position.
The glass panel cannot be moved up or down using your hand.
17. If the glass panel is loose, inspect the tightness of the glass panel mounting fasteners. Refer
to Sunroof Glass Panel Replacement .
18. Install the motor and the cover.

19. Turn the ignition to the ON position.
20. Verify the proper operation of the sunroof by cycling the sunroof from a closed position to the
vent position, and to a fully open position.
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Document ID: 398977
Page 1 of 4
Sunroof Drain Hose Replacement

Removal Procedure
1. Lower the headliner in order to access the drain hose connections. Refer to Headlining Trim
Panel Replacement in Interior Trim.
2. Remove the clamp (3) and the drain hose (2) from the drain spout.
3. Remove the interior moldings in order to access the drain hose retaining clips. Refer to
Windshield Pillar Garnish Molding Replacement or Rear Quarter Trim Panel Replacement in
Interior Trim.
4. Remove the tape from the drain hose.
5. Remove the front drain hose (1) from the retaining clips.
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Document ID: 398977
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6. Remove the rear upper drain hose (1) from the retaining clips.
7. Remove the clamp (3) and the drain hose (2) from the drain spout.
8. Remove the rear compartment trim panels. Refer to Rear Compartment Side Trim
Replacement - Left Side or Rear Compartment Side Trim Replacement - Right Side in Body
Rear End.
9. Remove the rear lower drain hose from the retaining clips.
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Document ID: 398977
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1. Clip the rear lower drain hose into position.

2. Install the rear compartment trim. Refer to Rear Compartment Side Trim Replacement - Left
Side or Rear Compartment Side Trim Replacement - Right Side in Body Rear End.
3. Clip the rear upper drain hose (1) into position.

4. Attach the hose (2) to the drain spout and secure the hose clamp (3).
5. Clip the front drain hose (1) into position.

6. Apply adhesive tape in order to secure the hose to the pillar.
7. Install the interior moldings. Refer to Windshield Pillar Garnish Molding Replacement or Rear
Quarter Trim Panel Replacement in Interior Trim.
Important: When installing the drain hose clamps (3), position the clamps in order to
maintain clearance between the clamps and the headliner.
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Document ID: 398977
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8. Install the drain hose (2) to the drain spout and secure the clamps (3).
9. Install the headliner to the roof. Refer to Headlining Trim Panel Replacement in Interior Trim.
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2/7/2011
Document ID: 398980
Page 1 of 6
Sunshade, Lifter Arm, Trough and Shield Replace

Sunshade Removal Procedure
1.
2.
3.
4.
5.
Remove the glass panel. Refer to Sunroof Glass Panel Replacement .

Cycle the unit to the vent position.
Slide the trough and shield forward.
Slide the sunshade (1) forward.
Lift and turn the front edge of the sunshade (1) in order to disengage the clips (3).
Sunshade Installation Procedure
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2/7/2011
Document ID: 398980
1.
2.
3.
4.
5.
Page 2 of 6
Slide the trough and shield (1) forward.

Flex the sunshade (2) in order to clear the stops (3).
Keeping the unit centered, slide the sunshade (2) to the rear.
Slide the sunshade (2) forward.
Install the glass panel. Refer to Sunroof Glass Panel Replacement .
Lifter Arm Removal Procedure

1. Remove the glass panel. Refer to Sunroof Glass Panel Replacement .
2. Cycle the unit to the rear until the lift pin is clear.
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3. Remove the cover plates (4) on each side.

4. Remove the 3 screws (8) on each side.
5. Cycle the unit (1) rearward in order to expose the openings in the track (2).
6. Remove the front lifter guides (3) from the track (4).
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Document ID: 398980
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7. Cycle the unit forward in order to release the lifter arm from the trolley.
Lifter Arm Installation Procedure
1.
2.
3.
4.
5.
Install the lifter arms (5).

Install the cover plates (4).
Install the machined screws (8).
Cycle the trough and shield assembly (1) to the full rear travel position.
Trough and Shield Removal Procedure

1. Remove the glass panel. Refer to Sunroof Glass Panel Replacement .
2. Cycle the unit to the rear until the lift pin is clear.
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3.
4.
5.
6.
7.
Page 5 of 6
Remove the cover plates (4).

Cycle the unit forward in order to expose the openings in the track (7).
Remove the lifter arms (5) by sliding the arms to the rear.
Lift out the arms through the openings in the track (7).
Cycle the trolley forward.
Do not disengage the cable from the transmission.
8. Pull the trough and shield assembly (1) forward.

9. Lift out the trough and shield assembly (1) through the opening in the track (7).
Trough and Shield Installation Procedure
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Document ID: 398980
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1. Install the guide shoes of the trough and shield assembly (1) into the opening (7) in the
track.
2. Engage the guide shoes of the trough and shield assembly (1) in the slot on the track (7).
3. Center the trough and shield assembly (1).
4. Push the trough and shield assembly (1) into the housing until the assembly is seated.
5. Install the lifter arms (5).
6. Install the machined screws (8) in order to secure the cover plates (4).
7. Cycle the trough and shield assembly (1) to full rear travel.
8. Install the glass panel. Refer to Sunroof Glass Panel Replacement .
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2/7/2011
Document ID: 280571
Page 1 of 2
Sunroof Air Deflector Replacement

Removal Procedure
1. Cycle the glass panel to the rear.
2. Push the pin (5) out of the deflector lift arm bracket.
Important: Note the position of the springs (3) before removal in order to ensure proper
operation after assembly.
3. Remove the spring (3).
4. Raise the deflector lift arm to the vertical position.
5. Snap the molded pin (5) out of the bracket (4).
Important: In order to ensure a secure fit, slightly squeeze the bracket arms (1) together
using pliers.
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Document ID: 280571
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1. Install the pin in the deflector arm.

Important: Return the springs to the position noted during removal.
2. Install the spring (3) and the pin (5) in the deflector lift arm (one per side).
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Document ID: 280577
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Sunroof Glass Panel Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the three screws from the trough and shield assembly.
Slide the trough and shield assembly to the rear.
Cycle the glass panel to the vent position.
Remove the 3 screws (1) from each side of the glass panel.
Remove the glass panel.
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1. Install the glass panel.

2. Install the 3 screws (1) to each side of the glass panel.
Tighten
3. Close the glass panel to the flush position.
4. Install the 3 screws to the trough and shield assembly.
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Document ID: 398985
Page 1 of 3
Power Sunroof Motor Replacement

Removal Procedure
Important: Whenever the motor is removed from the vehicle, both the track and the motor must
be synchronized before installation. Refer to Track and Motor Synchronization .
1. Lower the formed headliner at the rear.

2. Remove the fasteners attaching the motor to the roof panel.
Important: Note the location of the wire connectors before disconnecting.
3. Disconnect the wiring connectors from the motor.
4. Remove the power sunroof motor.
Important: Whenever the motor is removed from the vehicle, both the track and the motor must
be synchronized before installation. Refer to Track and Motor Synchronization .
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1. Connect the wiring harness connectors to the motor.

2. Synchronize the motor. Refer to Track and Motor Synchronization .
3. Install the motor to the roof and the transmission.

4. Install the fasteners attaching the motor to the roof panel.
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Document ID: 398985
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Tighten
5. Install the formed headliner.
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Document ID: 300049
Page 1 of 2
Power Sunroof Express Module Replacement

Removal Procedure
1. Lower the formed headliner at the rear. Refer to Headlining Trim Panel Replacement in
Interior Trim.
2. Remove the express module (2) by sliding out the slots in the bracket toward the center of
the vehicle.
3. Disconnect the wiring connector from the express module (2).
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Document ID: 300049
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1. Connect the wiring connector to the express module (2).

2. Install the express module (2).
3. Secure the formed headliner. Refer to Headlining Trim Panel Replacement in Interior Trim.
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2/7/2011
Document ID: 160564
Page 1 of 1
Sunroof Manual Operation
Important: The sunroof motor drive gear is made of nylon, care should be taken not to damage
the slot in the drive gear.
The sunroof can be operated manually by simultaneously depressing and turning the center slot in
the sunroof motor drive gear with a large straight-bladed screwdriver.
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Document ID: 307711
Page 1 of 2
Sunroof Glass Panel Seal Replacement

Removal Procedure
1. Remove the sunroof glass panel. Refer to Sunroof Glass Panel Replacement .
2. Pull seal (1) from the channel at the rim of the glass in order to remove the seal (1).
1. Clean the old adhesive from the channel at the rim of the glass.
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Document ID: 307711
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2. Apply a 152 mm (6 in) strip of adhesive to the side of the glass panel.
3. Start with the end of the seal (1) covering 77 mm (3.03 in) of the previously applied
adhesive.
Working around the glass panel, push the seal (1) into the channel (2).
4.
5.
6.
7.
8.
9.
10.
Cut free the end of the seal (1) at the side in order to allow a 3-5 mm (1/8-3/16 in) overlap.
Place a small amount of the adhesive on the free end of the seal (1).
Butt the ends of the seal (1) together, pushing the free end into the channel (2).
Force the remainder of the seal (1) into the channel (2).
Allow the adhesive to dry.
Adjust the sunroof glass panel in order to achieve good sealing action. Refer to Sunroof Panel
Vertical Adjustment .
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Document ID: 369886
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Restraints | Seat Belts |

Specification
Application
Metric
English
Front Driver/Passenger Seat Buckle Nut
28 Nm
21 lb ft
Front Driver/Passenger Seat Buckle-Side Belt Load Bar Bolt
40 Nm
30 lb ft
Front Driver/Passenger Seat Buckle-Side Dual Retractor Fasteners
25 Nm
18 lb ft
Front Driver/Passenger Seat Shoulder Belt Bolt
42 Nm
31 lb ft
Front Seat Shoulder Belt Guide Loop Bolt
42 Nm
31 lb ft
Rear Seat Anchor Bolt
35 Nm
26 lb ft
Rear Seat Center Nut
30 Nm
22 lb ft
Rear Seat Retractor-Side Belt Assembly Bolt
30 Nm
22 lb ft
2/7/2011
Document ID: 370393
Page 1 of 2
Seat Belt Buckle Replacement - Left Front

Removal Procedure
Caution: Load bar assembly must be replaced as a unit only. Do not substitute parts for any
reason, or personal injury could result in the event of a collision.
1. Remove the seat assembly. Refer to Seat Replacement in Seats.
2. Disconnect the load bar assembly from the tunnel and anchor nuts holding the seat adjusters
to the floor.
3. Disconnect the electrical connector at the buckle (drivers side only).
4. Drill out the rivet using a 3/16-inch bit.
5. Remove the load bar assembly.
Important: Driver and passenger buckle assemblies may be replaced separately if
necessary, by removing the nut with the seats still installed.
6. Remove the nut holding the buckle assembly to the load bar assembly.
7. Remove the buckle assembly.
2/7/2011
Document ID: 370393
Page 2 of 2
1. Connect the load bar assembly to the seat adjuster using a 3/16-inch rivet.
2. Connect the buckle assembly to the load bar assembly and secure with a nut.
Tighten
Caution: Make sure bolt is through both parts. Failure to do so will result in system failure,
leading to injury in the event of a collision.
3. Install the seat assembly. Secure the nuts to the seat adjuster and bolt for the center lap belt
and the load bar assembly. Refer to Seat Replacement in Seats and Carpet.
4. Connect the electrical connector to the seat harness (drivers side only).
2/7/2011
Document ID: 372405
Page 1 of 2
Seat Belt Buckle Replacement - Right Front

Removal Procedure
Caution: Load bar assembly must be replaced as a unit only. Do not substitute parts for any
reason, or personal injury could result in the event of a collision.
1. Remove the seat assembly. Refer to Seat Replacement in Seats and Carpet.
2. Disconnect the load bar assembly from the tunnel and anchor nuts holding the seat adjusters
to the floor.
3. Drill out the rivet using a 3/16-inch bit.
4. Remove the load bar assembly.
Important: Driver and passenger buckle assemblies may be replaced separately if
necessary, by removing the nut with the seats still installed.
5. Remove the nut holding the buckle assembly to the load bar assembly.
6. Remove the buckle assembly.
2/7/2011
Document ID: 372405
Page 2 of 2
1. Connect the load bar assembly to the seat adjuster using a 3/16-inch rivet.
2. Connect the buckle assembly to the load bar assembly and secure with a nut.
Tighten
Caution: Make sure bolt is through both parts. Failure to do so will result in system failure,
leading to injury in the event of a collision.
3. Install the seat assembly. Secure the nuts to the seat adjuster and bolt for the center lap belt
and the load bar assembly. Refer to Seat Replacement in Seats.
2/7/2011
Document ID: 370394
Page 1 of 2
Seat Belt Replacement - Center

Removal Procedure
1.
2.
3.
4.
5.
Remove the fasteners.

Remove the covers.
Remove the anchor bolts.
Separate the belt from the load bar assembly by bending away and discarding the ferrule.
Pull the center belt through the seat and the strap.
2/7/2011
Document ID: 370394
Page 2 of 2
1. Install the belt through the openings in the seat, if on the latch side, or through the strap
sewn to the side of the seat, if on the buckle side.
2. Align the tab on the belt with the slot on the load bar assembly.
3. Position the belt and the load bar assembly over the anchor hole in the tunnel.
Caution: When reinstalling load bar make sure anchor bolt is through the load bar, and
center belt holes. Center belt and load bar hole should be correctly lined up using the
projection on the belt and notch in load bar for reference. Failure to do so will result in injury
in the event of a collision.
4. Install the anchor bolts through the load bar assembly, lap belts and secure.
Tighten
Tighten the anchor bolts to 40 Nm (30 lb ft).
5. Install the load bar covers.
6. Install the fasteners in order to secure the covers.
2/7/2011
Document ID: 372341
Page 1 of 2
Rear Seat Belt Replacement

Removal Procedure
1. Remove the rear seat back. Refer to Rear Seat Back Replacement in Seats.
2. Remove the rear window trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
3. Remove the lap belt retractor anchor bolts and retractors.

4. Remove shoulder and lap belt retractors from vehicle.
2/7/2011
Document ID: 372341
Page 2 of 2
1. Position tab on the shoulder retractor with the hole in the shelf panel. Place the shoulder belt
retractor on the shelf panel and install the anchor bolts.
2. Install the anchor bolt.
Tighten
Tighten the anchor bolt to 30 Nm (22 lb ft).
3. Position the lap belt on the floor so the tabs on the bottom of the retractor are on each side
of the bump on the floor pan. The bump is forward of the anchor hole. Ensure that the
webbing is not twisted.
4. Install the anchor nuts.
Tighten
5. Install the rear window trim panel. Refer to Rear Window Shelf Trim Panel Replacement in
Interior Trim.
6. Install the rear seat back. Refer to Rear Seat Back Replacement in Seats.
2/7/2011
Document ID: 370540
Page 1 of 2
Seat Belt Replacement - Center Rear

Removal Procedure
2. Remove the nuts (3) attaching belt assembly (4)to floor pan assembly.
3. Remove the belt assembly (4) (both sides).
2/7/2011
Document ID: 370540
Page 2 of 2
1. Install the belt assembly (4) to the studs on the floorpan.

2. Install the two nuts (3).
Tighten
2/7/2011
Document ID: 370530
Page 1 of 3
Seat Belt Retractor Replacement - Left Front

Removal Procedure
Caution: The seat belt assembly and/or bracket assembly must be replaced as a unit only.
Do not substitute parts for any reason, or personal injury could result.
1. Remove the center pillar trim. Refer to Center Pillar Garnish Molding Replacement in Interior
Trim.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the fasteners and slide track.

Remove the anchor bolt and guide loop.
Remove the fastener and intermediate guide.
Remove the carpet retainer.
Move the seat full forward in order to remove the anchor bolt.
Remove the dual retractor.
Remove the fasteners from the shoulder belt guide adjustment bracket assembly.
Remove the shoulder belt guide adjustment bracket assembly.
2/7/2011
Document ID: 370530
Page 2 of 3
1. Install the shoulder belt guide bracket assembly and the fasteners into the center pillar near
the roof.
Tighten
Tighten the fasteners to 25 Nm (19 lb ft)
2. Install the anchor bolt for the dual retractor into center pillar at the rocker.
Tighten
3. Install the anchor bolt for the guide loop into the bracket assembly.
Tighten
Important: When installing slide track, care must be taken to engage the head of the guide
loop into the socket on the back of the slide track (5 positions of adjustment are provided).
After the trim is installed a check should be made to see if the slide track locks into all
5 positions.
4. Install the slide track and the 2 fasteners.
Tighten
2/7/2011
Document ID: 370530
Page 3 of 3
Tighten the two fasteners to 1.9 Nm (16 lb in).

5. Install the intermediate guide and fastener.
Tighten
Tighten the intermediate guide fastener to 1.9 Nm (16 lb in).
6. Install the center pillar trim. Refer to Center Pillar Garnish Molding Replacement in Interior
Trim.
2/7/2011
Document ID: 372407
Page 1 of 2
Seat Belt Retractor Replacement - Right Front

Removal Procedure
Caution: The seat belt assembly and/or bracket assembly must be replaced as a unit only.
Do not substitute parts for any reason, or personal injury could result.
1. Remove the center pillar trim. Refer to Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
2.
3.
4.
5.
6.
7.
8.
Remove
Remove
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
the
the
fasteners and the slide track.

anchor bolt and the guide loop.
fastener and the intermediate guide.
anchor bolt.
dual retractor
fasteners from the bracket assembly.
bracket assembly.
1. Install the 2 fasteners and the bracket assembly into the center pillar near the roof.
2/7/2011
Document ID: 372407
Page 2 of 2
Tighten
Tighten the fasteners to 25 Nm (19 lb ft)
2. Install the anchor bolt for dual retractor into center pillar at rocker.
Tighten
3. Install the anchor bolt for the guide loop into the bracket assembly.
Tighten
Important: When installing slide track, care must be taken to engage the head of the guide
loop into the socket on the back of the slide track (5 positions of adjustment are provided).
After the trim is installed a check should be made to see if the slide track locks into all
5 positions.
4. Install the slide track and 2 fasteners.
Tighten
Tighten the two slide track fasteners to 1.9 Nm (16 lb in).
5. Install the intermediate guide and fastener.
Tighten
Tighten the intermediate guide fastener to 1.9 Nm (16 lb in).
6. Install the center pillar trim. Refer to Refer to Center Pillar Garnish Molding Replacement in
Interior Trim.
2/7/2011
Document ID: 299727
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Body and Accessories | Seats |

Specification
Application
Metric
English
Load Bar Bolt
42 Nm
31 lb ft
Rear Seat Lap Belt Nut
35 Nm
26 lb ft
Seat Adjuster to Floor Pan Nut
34 Nm
25 lb ft
Seat Adjuster to Seat Cushion Frame Bolts
24 Nm
18 lb ft
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2/7/2011
Document ID: 344255
Page 1 of 1
Cell 140: LH Power Seat
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2/7/2011
Document ID: 344264
Page 1 of 1
Cell 140: RH Power Seat
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2/7/2011
Document ID: 343407
Page 1 of 1
Passenger Compartment, Under the Front Seats
(1) C345 (Pontiac With AL7) C313 (Oldsmobile)

(2) C303 (Buick, Oldsmobile)
(3) LH Seat Switch (Oldsmobile/Pontiac w/AG1,AG2)
(4) C324 (Buick, Oldsmobile)
(5) Seat Module
(6) C326 (Buick/Oldsmobile) C323 (Pontiac Without AL7) C353 (Pontiac With AL7)
(7) C341
(8) RH Seat Switch (Oldsmobile/Pontiac w/AG1,AG2)
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2/7/2011
Document ID: 343455
Page 1 of 1
Rear Compartment (Pontiac)
(1) License Lamp

(2) License Lamp
(3) C404
(4) S429, S430
(5) Inflator Switch
(6) C405
(7) S431 S432
(8) C401
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2/7/2011
Document ID: 400522
Page 1 of 1
Passenger Compartment, On the Door Armrest
(1) Mirror Switch (Buick)

(2) LH Seat Switch -- RH Similar (Buick)
(3) LH Front Power Window Switch -- RH Similar (Buick)
(4) Mirror Switch (Oldsmobile)
(5) LH Front Power Window Switch -- RH Similar (Oldsmobile)
(6) LH Power Door Lock Switch -- RH Similar (Pontiac)
(7) LH Front Power Window Switch -- RH Similar (Pontiac)
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2/7/2011
Document ID: 359861
Page 1 of 11
Power Seat Connector End Views

Table 1:
Console Seat Switch C3
Table 2:
LH Seat Switch
Table 3:
LH Seat Switch
Table 4:
Memory Seat / Mirror Module C1
Table 5:
Table 6:
Table 7:
RH Seat Cushion Air Valve
Table 8:
RH Seat Switch (Oldsmobile)
Table 9:
Seat Air Control Module
Table 10: Seat Control Module C1 (Pontiac)

Table 12: Seat Control Module C2 (Pontiac with AL7)
Table 13: Seat Control Module C2
Console Seat Switch C3
Connector Part
Information
12064872
10-Way M Metri-Pak 150 Series (BLU)
Pin
Wire Color
Circuit
No.
DK GRN
1518
Power Seat Switch Input - Front Vertical - Up
DK BLU
1520
Power Seat Switch Input - Front Vertical - Down
YEL
1519
Power Seat Switch Input - Rear Vertical Up
LT BLU
1521
Power Seat Switch Input - Rear Vertical Down
TAN
1522
Power Seat Switch Input - Horizontal Fore
LT GRN
1523
Power Seat Switch Input - Horizontal Back
BLK/GRN
1269
Power Seat Switch Input - Recline Forward
Function
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2/7/2011
Document ID: 359861
Page 2 of 11
WHT/DK GRN
1270
--
--
BRN
1674
Power Seat Switch Input - Recline Back

Not Used
Power Seat Switch Input - Driver/Passenger
Select
LH Seat Switch
Connector Part
Information
12129431
Pin
Wire Color
Circuit
No.
--
--
Not Used
GRY
Instrument Panel Feed
WHT
615
Memory Seat Switch Signal - Memory 1
ORN
614
Memory Seat Switch Signal - Set
PPL
616
Memory Seat Switch Signal - Memory 2
ORN
640
Fuse Output Battery Type III Fuse
BLK
1250
ORN
640
DK BLU
2878
Power Seat Motor Feed - Drivers - Front Vertical

Down
DK BLU
1520
Power Seat Switch Signal - Front Vertical Down
DK GRN
286
Power Seat Motor Feed - Drivers - Front Vertical

Up
TAN
1158B
TAN
285
TAN
1522
Power Seat Switxh Signal - Horizontal Fore
LT GRN
2840
Power Seat Motor Feed - Driver and Vertical Up
LT GRN
1523
Power Seat Switch Signal - Horizontal Fore
LT BLU
283
Function
Ground
Fuse Output Battery - Type III
Hand Set Fax Data Signal

Power Seat Motor Feed - Driver s- Horizontal Fore
Power Seat Motor Feed - Drivers Rear Vertical

Down
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2/7/2011
Document ID: 359861
Page 3 of 11
Power Seat Switch Signal - Rear Vertical Down
LT BLU
1521
YEL
282
YEL
1519
Power Seat Switch Signal - Rear Vertical Up
LT BLU
277
Power Seat Motor Feed - Drivers Recline Aft
LT BLU
277
Power Seat Motor Feed - Drivers Recline Aft
LT GRN
276
Power Seat Motor Feed - Drivers Recline Fore
Power Seat Motor Feed - Drivers Rear Vertical Up
LH Seat Switch
Connector Part
Information
12034024
11-Way F Pin Grip (BLK)
Pin
Wire Color
Circuit
No.
BLK
1250
LT BLU
283
Power Seat Motor Feed Driver Rear Vertical

Down
YEL
282
Power Seat Motor Feed Driver Rear Vertical Up
LT GRN
284
Power Seat Motor Feed Driver Horizontal Aft
TAN
285
Power Seat Motor Feed Driver Horizontal Fore
DK BLU
287
Power Seat Motor Feed Driver Front Vertical

Down
DK GRN
286
Power Seat Motor Feed Driver Front Vertical Up
Ground
Not Used
H-K
L
Function
ORN
1340
Fuse Output Battery
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2/7/2011
Document ID: 359861
Page 4 of 11
12064749
2-Way F Metri - Pack 480 Series (BLK)
Pin
Wire Color
Circuit No.
ORN
1340
BLK
1250
Ground
Function
Connector Part
Information
12110207
32-Way F Micro - Pack 100 Series (BLU)
Pin
Wire Color
Circuit
No.
C1
DK GRN
784
Memory Mirror Position Input - Left Vertical Motor
C2
GRY/BLK
786
Memory Mirror Position Input - Left Horizontal Motor
C3
BRN
787
Memory Mirror Position Input - Right Vertical Motor
C4
GRY
1831
Power Mirror Switch Input - Right Horizontal Motor Left
C5
LT GRN
275
C6
BRN/WHT
1832
Function
Neutral Safety Switch Output - Park

Power Mirror Switch Input - Right Vertical Motor - Up
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2/7/2011
Document ID: 359861
Page 5 of 11
C7
LT GRN
1523
C8
YEL
1517
Power Mirror Switch Input - Left Vertical Motor - Up
C9
PPL
616
Memory Seat Switch Input - Memory 2
C10
BLK
782
Sensor Return - Memory Seat / Mirror
C11
PPL
1985
C12
PNK
39
C13
LT GRN
276
C14
DK BLU
1520
Power Seat Switch Input - Front Vertical Down
C15
LT BLU
1521
C16
LT BLU
277
Power Seat Motor Control - Driver - Recline Back
D1
LT BLU/BLK
785
Memory Mirror Position Sensor Input - Right

Horizontal Motor
D2
GRY
788
Memory Mirror Position Control - 5 Volt Reference
D3
TAN
568
Memory Seat Position Sensor Input - Rear Vertical

Motor
D4
DK GRN
569
Memory Seat Position Sensor Input - Horizontal

Motor
D5
WHT
615
Memory Switch Input - Memory 1
D6
RED/WHT
1513
Power Mirror Switch Input - Right Horizontal Motor Right
D7
WHT
1512
Power Mirror Switch Input - Left Horizontal Motor Right
D8
ORN
614
Memory Seat Switch Input - Set
D9
BRN/WHT
557
Memory Seat Position Sensor Input - Front Vertical

Motor
D10
WHT/BLK
570
Memory Seat Position Sensor Input - Driver Recline

Motor
D11
LT BLU
1516
Power Mirror Switch Input - Left Horizontal Motor Left
D12
YEL/BLK
571
D13
--
--
D14
TAN
1522
D15
DK GRN
1518
D16
YEL
1519
Memory Seat / Mirror Module Input - Memory

Personalization
Fused Output - IGN
Power Seat Motor Control - Driver - Recline Fore
Diagnostic Input - Memory Seat

Not Used
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2/7/2011
Document ID: 359861
Connector Part
Information
Page 6 of 11
12064762
6-Way F Metri - Pack 150 Series (GRY)
Pin
Wire Color
Circuit
No.
BRN/WHT
1498
WHT
818
Power Mirror Motor Control - Left Horizontal Motor Right Direction
YEL
88
Power Mirror Motor Control - Left Vertical Motor - Up

Direction
LT BLU
82
Power Mirror Motor Control - Left Horizontal Motor Left Direction
RED/WHT
881
GRY
90
Function
Power Mirror Motor Control - Right Vertical Motor - Up
Direction
Power Mirror Motor Control - Right Horizontal Motor Right Direction

Power Mirror Control - Right Horizontal Motor - Left
Direction
RH Seat Cushion Air Valve
Connector Part
Information
12064769
10-Way F Metri - Pack 150 Series (NAT)
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2/7/2011
Document ID: 359861
Page 7 of 11
Pin
Wire Color
Circuit
No.
--
--
LT BLU
1259
Pneumatic Seat Solenoid Control-Lower LumbarPassenger
PNK
1265
Pneumatic Seat Solenoid Control-Lateral- Passenger
D-E
--
--
RED
798
--
--
PNK
1260
Pneumatic Seat Solenoid Lumbar-Passenger
ORN
1261
Pneumatic Seat Solenoid Upper Lumbar-Passenger
PNK
1265
Pneumatic Seat Solenoid Control-Lateral- Passenger
Function
Not Used
Not Used
Pneumatic Seat Solenoid Output - Passenger
Not Used
RH Seat Switch (Oldsmobile)
Connector Part
Information
R12129431
16-Way F Metri-Pack 280 (ACT) Series (BLK)
Pin
Wire Color
Circuit
No.
ORN
1340
Fuse Output Battery
BLK
1450
Ground
Not Used
C-F
G
Function
GRY
Instrument Panel Lamp Control

Not Used
DK GRN
76
Power Seat Motor Control-Passenger- Recline Fore
DK BLU
77
Power Seat Motor Control-Passenger- Recline Back
YEL
288
Power Seat Motor Control-Passenger- Rear Vertical

Up
LT BLU
289
Power Seat Motor Control-Passenger- Rear Vertical

Down
LT GRN
290
Power Seat Motor Control-Passenger- Horizontal

Back
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Document ID: 359861
Page 8 of 11
TAN
296
Power Seat Motor Control-Passenger- Horizontal

Fore
DK GRN
297
Power Seat Motor Control-Passenger- Front Vertical

Up
DK BLU
298
Power Seat Motor Control-Passenger- Front Vertical

Down
Seat Air Control Module
12064998
Pin
Wire Color
Circuit No.
Function
BLK
769
BLK
1250
TAN
768
Power Seat Motor Control-Driver Lumbar Up
WHT
766
Pneumatic Seat Relay Control-Coil Driver Inflate
BLK
1250
Ground
ORN
1340
Fuse Output-Battery
PPL
767
Power Seat Motor Control-Driver Lumbar Down
GRY
764
Pneumatic Seat Relay Control-Coil Driver Deflate
Pneumatic Seat Select Switch

Ground
Seat Control Module C1 (Pontiac)
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2/7/2011
Document ID: 359861
Page 9 of 11
12064749
Pin
Wire Color
Circuit No.
ORN
1340
Fuse Output - Battery - Type III Fuse
BLK
1250
Ground
Function
Connector Part
Information
12064752
Pin
Wire Color
Circuit
No.
DK BLU
298
Power Seat Motor Control - Passenger - Front

Vertical Down
LT BLU
289
Power Seat Motor Control - Passenger - Rear Vertical

Down
LT GRN
290
Power Seat Motor Control - Passenger - Horizontal

Back
DK BLU
1247
DK BLU
77
Power Seat Motor Control - Passenger - Recline Back
--
--
Not Used
Function
Power Seat Motor Output - Passenger
Seat Control Module C2 (Pontiac with AL7)
tomsn048@gmail.com
2/7/2011
Document ID: 359861
Connector Part
Information
Page 10 of 11
12064770
10-Way M Metri-Pack 150 Series (NAT)
Pin
Wire Color
Circuit
No.
GRY
764
Pneumatic Seat Relay Control-Coil-Driver Deflate
RED
798
Pneumatic Seat Solenoid Output-Passenger Seat
ORN
640
BLK
769
Pneumatic Seat Select Switch Output - Driver
BLK
1250
Ground
LT BLU
1259
Pneumatic Seat Solenoid Control - Lower Lumbar Passenger
PNK
1260
Pneumatic Seat Solenoid Control - Lumbar Passenger
ORN
1261
Pneumatic Seat Solenoid Control - Upper Lumbar Passenger
PNK
1265
Pneumatic Seat Solenoid Control - Lateral Passenger
WHT
766
Function
Pneumatic Seat Relay Control Coil - Driver - Inflate
Seat Control Module C2
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2/7/2011
Document ID: 359861
Page 11 of 11
12064871
10-Way F Metri-Pak 150 Series (BLU)
Pin
Wire Color
Circuit No.
DK GRN
1518
Power Seat Switch Input - Front Vertical Up
DK BLU
1520
Power Seat Switch Input - Front Vertical Down
YEL
1519
LT BLU
1521
TAN
1522
LT GRN
1523
BLK GRN
1269
Power Seat Switch Input - Recline Forward
WHT GRN
1270
Power Seat Switch Input - Recline Back
--
--
BRN
1674
Function
Not Used
Power Seat Switch - Driver/Passenger Select
Connector Part
Information
12064752
Pin
Wire Color
Circuit
No.
DK BLU
298
Power Seat Motor Control - Passenger - Front

Vertical Down
LT BLU
289
Power Seat Motor Control - Passenger - Rear Vertical

Down
LT GRN
290
Power Seat Motor Control - Passenger - Horizontal

Back
DK BLU
1247
DK BLU
77
Power Seat Motor Control - Passenger - Recline Back
--
--
Not Used
Function
Power Seat Motor Output - Passenger
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2/7/2011
Document ID: 299737
Page 1 of 2
Power Seat Switch Replacement

Removal Procedure
1.
2.
3.
4.
Remove the fasteners (2) attaching the seat switch bezel to the seat.
Partially remove the switch bezel (1).
Remove the seat switch. Refer to one of the following procedures:
Power Seat Switch Replacement in Doors.
Console Front Trim Plate Replacement in Instrument Panel, Gauges and Console.
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2/7/2011
Document ID: 299737
Page 2 of 2
1. Install the seat switch. Refer to one of the following procedures:

Console Front Trim Plate Replacement in Instrument Panel, Gauges and Console.
2.
3.
4.
5.
Power Seat Switch Replacement in Doors.

Install the switch bezel to the seat.
Install the fasteners (2).
Verify that the seat operates correctly.
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2/7/2011
Document ID: 299730
Page 1 of 4
Driver or Passenger Seat Replacement

(Buick/Oldsmobile)
Removal Procedure
1. Remove the fasteners that retain the floor support covers.
2. Remove the floor support covers.
3.
4.
5.
6.
7.
Remove the load bar cover.

Move the seat to the full rearward position.
Remove the front floor support covers.
Remove the front nuts that retain the adjuster to the floor pan.
Move the seat to the full forward position.
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Document ID: 299730
Page 2 of 4
Caution: On seats with a manual adjuster, failure to place the seat in the full forward
position prior to removal of the rear attaching nuts could allow the seat track to suddenly
spring forward, resulting in personal injury.
8. Remove the rear nuts that retain the adjuster (3) to the floor pan. (The insert shows the
manual adjuster.)
9. Remove the load bar bolt (4).
10. Tilt the seat forward.
11. Disconnect the following components:
The electrical connectors (2)
The air hose (if equipped)
The HVAC duct (5) at the armrest (if equipped)
12. Remove the rear seat cushion, prior to front seat removal. Refer to Rear Seat Cushion
Replacement .
13. Remove the left front seat out the left rear door, with the aid from an assistant.
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Document ID: 299730
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1. Install the front seat, with the aid from an assistant, through the left rear door opening.
3. Connect or install the following components:
The air hose (if equipped)
The HVAC duct (5) at the armrest (if equipped)
4. Install the load bar bolt (4).
Tighten
Tighten the load bar bolt to 35 Nm (26 lb ft).
5. Install the rear nuts in order to attach the adjuster (3) to the floor pan. (The insert shows the
manual adjuster).
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Document ID: 299730
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Tighten
Tighten the rear nuts to 34 Nm (25 lb ft).
6. Install the front nuts in order to attach the adjuster (3) to the floor pan. (The insert shows
the manual adjuster.)
Tighten
Tighten the front nuts to 34 Nm (25 lb ft).
7.
8.
9.
10.

Install the load bar cover.
Install the floor support covers front and rear.
Install the floor support cover fasteners front and rear.
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Document ID: 321586
Page 1 of 4
Driver or Passenger Seat Replacement (Pontiac)

Removal Procedure
1.
2.
3.
4.
5.
6.
Remove the fasteners that retain the floor support covers.

Remove the floor support covers.
Remove the load bar cover.
Remove the front nuts (1) that attach the adjuster to the floor pan.
Caution: On seats with a manual adjuster, failure to place the seat in the full forward
position prior to removal of the rear attaching nuts could allow the seat track to suddenly
spring forward, resulting in personal injury.
7. Remove the rear nuts (2) that attach the adjuster to the floor pan.
8. Remove the load bar bolt (3).
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Document ID: 321586
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9. Tilt the seat rearward.

10. Disconnect the following components:
The electrical connectors
The air hose
The HVAC duct at the armrest, where applicable.
11. Remove the seat with aid from an assistant.
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Document ID: 321586
Page 3 of 4
Object Number: 314048 Size: MH
1. Install the seat with aid from an assistant.
2. Connect or install the following components:

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Document ID: 321586
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The air hose

The HVAC duct at the armrest, where applicable.
3. Install the load bar bolt (3).
Tighten
Tighten the load bar bolt to 42 Nm (31 lb ft).
4. Install the rear nuts in order to attach the adjuster to the floor pan.
Tighten
Tighten the rear nuts (2) to 34 Nm (25 lb ft).
5. Install the front nuts in order to attach the adjuster to the floor pan.
Tighten
Tighten the front nuts (1) to 34 Nm (25 lb ft).
6.
7.
8.
9.

Install the load bar cover.
Install the floor support covers.
Tighten the floor support cover fasteners.
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Document ID: 299731
Page 1 of 3
Front Seat Cushion Replacement

Removal Procedure
1. In order to ease in the removal of the adjuster, raise the seat back to the fully inclined (up)
position before you remove the seat
2. Remove the seat. Refer to Seat Replacement .
3. Place the seat on a clean, protected surface.
4. Remove the adjusters.
5. Disconnect the air lines, if necessary.
6. Remove the following components, if necessary.
The side trim panel fasteners
The front trim panel fasteners
7. Disconnect the recliner switch electrical connectors, if necessary.
8. Remove the panels, if necessary.
9.
10.
11.
12.
13.
14.
15.
16.
Remove the hog rings (1, 2, 3) from the seat cover.

Disconnect the J-section retainers (5).
Pull the seat cover back to access the pivot bolts.
Remove the recliners. Refer to Front Seat Power Recliner Replacement or Seat Back Recliner
Replacement .
Remove the right pivot bolt.
Remove the left pivot bolt.
Note the routing of the air lines.
Remove the seat back.
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17.
18.
19.
20.
Page 2 of 3
Disengage the hook and loop strips (2).

Remove the seat cover from the cushion.
Remove the hog rings retaining the cushion.
Remove the cushion.
1. Install the cushion to the frame.

2. Install the hog rings to the cushion.
3. Install the seat cover (1) to the cushion.
Smooth out the wrinkles.
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Page 3 of 3
4. Install the seat back.

Check air line routing.
5. Install the left pivot bolt.
6. Install the right pivot bolt.
7. Install the recliners. Refer to Front Seat Power Recliner Replacement or Seat Back Recliner
Replacement .
8.
9.
10.
11.
12.
Connect the J-section retainers (5).

Install the hog rings (1, 2, 3) to the seat cover.
Install the panels, if necessary.
Connect the recliner switch electrical connectors, if necessary.
Install the following components, if necessary:
The front trim panel fasteners
The side trim panel fasteners

13. Connect the air lines, if necessary.
14. Install the following components to the seat:
The adjusters
The 4 bolts
15. Install the seat. Refer to Seat Replacement .
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Document ID: 299732
Page 1 of 4
Front Seat Cushion Cover Replacement

Removal Procedure
1. Remove the seat. Refer to Seat Replacement in order to remove the following components:
The seat
The adjusters
2. Remove the seat back (2) from the seat.

3. Remove the recliner handle or the power recliner switch, if applicable.
4. Remove the armrest. Refer to Front Seat Armrest Replacement .
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2/7/2011
Document ID: 299732
5.
6.
7.
8.
9.
Remove
Remove
Remove
Remove
Remove
the
the
the
the
the
Page 2 of 4
hog rings (1) and the cushion cover.

J-section retainer (5).
hog rings and the pad from the springs (3).
pad and the cover from the frame.
hog rings (2) and the cover from the bottom of the cushion.
10. Remove the hog rings in the pad behind the cover.
11. Disengage the hook and loop strips (2).
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1. Align the locating holes in the cover (1) with the work lines on the pad.
2. Install the hog rings in the pad behind the cover.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Install
Install
Install
Install
Install
the
the
the
the
the
hog rings (2) and the cover to the bottom of the cushion.
pad and the cover to the frame.
hog rings and the pad to the springs (3).
J-section retainer (5).
hog rings (1) and the cushion cover.
Install the armrest. Refer to Front Seat Armrest Replacement .

Install the recliner handle or the power recliner switch, if applicable.
Install the seatback (2) to the seat.
Refer to Seat Replacement in order to install the following components:
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The seat
The adjusters
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Document ID: 299733
Page 1 of 2
Front Seat Back Replacement (Buick)

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Remove the front seat cushion. Refer to Front Seat Cushion Replacement .
Remove the zipper or the J-retainer at the bottom of the seat back.
Remove the hook-and-loop strip from each side of the plate assembly.
Peel back the cover as far as the center insert tie-down wire.
Remove the hog rings.
Remove the back insert pads.
Peel back the cover (2).
Remove the hog rings from each side of the upper bolster tie-down wires.
Remove the hog rings from the rear bottom tie-down of the seat back.
Remove the hog rings from the excess welt cords on each side of the seat back.
Remove the head restraint (3). Refer to Front Seat Head Restraint Replacement .
Remove the cover.
Remove the pad from the seat back frame (1).
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Document ID: 299733
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Install
Install
Install
Install
Install
Install
Install
Install
Install
Install
Install
the
the
the
the
the
the
the
the
the
the
the
Page 2 of 2
pad to the seat back frame (1).

cover (2).
head restraint (3). Refer to Front Seat Head Restraint Replacement .
hog rings to the excess welt cords on each side of the seat back.
hog rings to the rear bottom tie-down of the seat back.
hog rings to each side of the upper bolster tie-down wires.
back insert pads.
hog rings.
hook-and-loop strip from each side of the plate assembly.
zipper or the J-retainer at the bottom of the seat back.
seat cushion. Refer to Front Seat Cushion Replacement .
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Document ID: 321589
Page 1 of 5
Front Seat Back Replacement (Oldsmobile)

Removal Procedure
1. Remove the front seat cushion. Refer to Front Seat Cushion Replacement .
2. Remove the zipper or the J-retainer at the bottom of the seat back.
3.
4.
5.
6.
Remove the hook-and-loop strip (1) from each side of the plate assembly.
Peel back the cover as far as the center insert tie-down wire.
Remove the hog rings.
Remove the back insert pads (2).
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Document ID: 321589
7.
8.
9.
10.
11.
Page 2 of 5
Peel back the cover (2).

Remove the hog rings (1) from each side of the upper bolster tie-down wires.
Remove the hog rings (1) from the rear bottom tie-down of the seat back.
Remove the hog rings (1) from the excess welt cords on each side of the seat back.
Remove the head restraint. Refer to Front Seat Head Restraint Replacement .
12. Remove the cover (2).
13. Remove the blue air line (8) from the lumbar bladder (4).
14. Remove the bladder (4).
15. Remove the following air lines from the contour bladders:
The green air line (9)
The orange air line (7)
16. Unsnap the bolster bladder assembly from each side of the seat back mounting hinges.
17. Unsnap the bladders from each side of the upper contour plates.
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18. Remove the pad (1) from the seat back frame.
1. Install the pad (1) to the seat-back frame.
2. Snap the bladders into the upper contour plates on each side.
3. Snap the bolster bladder assembly to the mounting hinges on the seat back.
4. Install the following air lines to the contour bladder:
The green air line (9)
The orange air line (7)
5. Install the lumbar bladder (8).
6. Install the blue air line (8) to the lumbar bladder (8).
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7. Install the cover (2).

8. Install the head restraint. Refer to Front Seat Head Restraint Replacement .
9. Install the hog ring welt cords (1) on each side of the seat back.
10. Install the hog ring seat back to the bottom tie-down.
11. Install the hog ring cover (2) at each side of the upper bolster tie-down wires.
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Document ID: 321589
12.
13.
14.
15.
16.
Install
Install
Install
Install
Install
Page 5 of 5
the back insert pads (2).

the hog ring cover as far as the center insert tie-down wire.
each side of the plate assembly.
the zipper or the J-retainer at the bottom of the seat back.
the seat cushion. Refer to Front Seat Cushion Replacement .
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2/7/2011
Document ID: 414425
Page 1 of 6
Front Seat Back Replacement (Pontiac With AL7)

Removal Procedure
1.
2.
3.
4.
5.
6.
7.
8.
Remove the front seat. Refer to Seat Replacement .

Remove the headrest. Refer to Front Seat Head Restraint Replacement .
Remove the headrest guides.
Remove the seat cushion. Refer to Front Seat Cushion Replacement .
Disconnect the J-retainer at the bottom of the seat back.
Remove the rear finish panel.
Disconnect J-retainer from seat back outer support.
Remove the hog rings from the seat back cover.
9. Remove the seat back cover (2).

10. Remove the seat back pad.
11. Disconnect the air hoses from the lumbar bladder.
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12. Remove the lumbar bladder (1).
13. Disconnect the air hoses (1) from the contour bladders.
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14. Remove the retainers from the contour bladders (1).

15. Remove the bladders.
16. Remove the retainers from the contour plates (1).

17. Remove the contour plates.
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1. Install the contour plates to the seat frame (2).

Install the fasteners.
2. Install the contour bladders.
3. Install the contour bladder retainers (1).

4. Connect the air hoses to the contour bladders.
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Document ID: 414425
Page 5 of 6
5. Install the lumbar bladder (1).
6.
7.
8.
9.
10.
Connect the green air hose to the lumbar bladder (1).

Connect the white air hose to the lumbar bladder (2).
Connect the yellow air hose to the lumbar bladder (3).
Connect the blue air hose to the lumbar bladder (4).
Install the seat back pad.
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11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page 6 of 6
Install the seat back cover (2).

Smooth out the wrinkles.
Install the hog rings to the seat back cover in order to secure.
Fasten the seat back cover J-retainer to the seat back frame outer support.
Install the seatback finish panel.
Connect the J-retainer at the bottom of the seat back.
Install the seat cushion. Refer to Front Seat Cushion Replacement .
Install the headrest guides.
Install the headrest. Refer to Front Seat Head Restraint Replacement .
Install the front seat. Refer to Seat Replacement .
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Document ID: 299734
Page 1 of 3
Seat Back Cover and Pad Replacement

Removal Procedure
1. Remove the head restraint and guides. Refer to Front Seat Head Restraint Replacement .
2. Refer to Seat Replacement in order to remove the following components:
The seat
The seat adjusters
3. Remove the recliner attachment roll pins at the rear of the seat. Refer to Seat Back Recliner
Replacement .
4. Remove the assist strap, if applicable.

5. Remove the pivot bolts (3).
On the passenger side, push down the trim cover, remove the hog rings and pull up in
order to gain access to the bolts.
On the driver side, the outboard bolt is accessible from the side. Push down on the trim at
the rear of the seat. The inboard bolt is located on the underside of the seat, near the
armrest.
6. Remove the seat back (2) from the cushion (3).
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Page 2 of 3
7. Disengage the J-section retainer (1) at the bottom of the seat back.
8. Disengage the hook-and-loop attachments inside the cover.
9. Remove the cover (4) from the pad (3).
1. Install the cover (4) onto the pad (3). Align the locating holes in the cover to the grooves in
the pad (3).
2. Install the hook-and-loop attachments on the cover to the pad.
3. Install the J-section retainer (1) at the bottom of the seatback.
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4. Install the pivot bolts (3) in order to attach the seat back (2) to the seat cushion (4).
5. Install the assist strap, if applicable.
6. Install the recliner attachment roll pins at the rear of the seat. Refer to Seat Back Recliner
Replacement .
7. Refer to Seat Replacement in order to install the following components:
The seat
The seat adjusters
8. Install the head restraint and guides. Refer to Front Seat Head Restraint Replacement .
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Document ID: 299735
Page 1 of 4
Seat Back Recliner Replacement

Removal Procedure
1. Refer to Seat Replacement in order to remove the following components:
The seat
The seat adjusters
2. Using a flat-bladed tool, remove the retaining clips (1) from the recliner handle (3).
3. Remove the recliner handle (3).
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4. Disconnect the J-section retainer (5) on the seat cushion cover.

Pull the cover out of the way.
5. Remove the hog rings (1) from the guide pin at the carpet flap covering (4) at the rear of the
recliner.
6. Using a small hammer and a punch, remove the clips (1) from the guide pins (2).
7. Remove the recliner assembly (3).
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1. Install the recliner assembly (3).

2. Install the guide pin (2) at the front of the recliner. Press firmly in order to fit the guide pin
into place.
3. Install the guide pin (2) at the rear of the recliner. Press firmly in order to fit the guide pin
into place.
4. Install the retainer clips (1).
5. Install the hog rings (1) to the carpet flap (4) in order to cover the guide pin at the rear of
the recliner.
6. Install the J-section retainer (5) on the cover.
7. Install the retaining clip (1) on the handle.

8. Install the recliner handle.
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9. Refer to Seat Replacement in order to install the following components:

The seat
The seat adjusters
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Page 1 of 3
Front Seat Power Recliner Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the seat. Refer to Seat Replacement .

Place the seat on a clean, protected surface.
Remove the seat adjuster retainers.
Disconnect the electrical connectors, if necessary.
Remove the seat adjusters from the seat.
6.
7.
8.
9.
Remove the hog rings (1, 2, 3) from the seat cover.

Pull back the trim flap.
Disconnect the side J-retainers (5).
Pull back the seat cover to expose the recliner roll pins.
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10.
11.
12.
13.
14.
Page 2 of 3
Remove the roll pins from the seat back frame.

Disconnect the air lines, if necessary.
Remove the fasteners from the power recliner motor mounting bracket.
Release the actuator from the seat frame by lifting actuator shafts upward.
Remove the recliner assembly.
1.
2.
3.
4.
Install the recliner assembly vertically then rotate to the downward position.
Install the fasteners to the power recliner motor mounting bracket.
Connect the air lines, if necessary.
Install the roll pins to the seat back frame.
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5.
6.
7.
8.
9.
10.
Page 3 of 3
Connect the side J-retainers (5).

Install the hog ring (1, 2, 3) to the seat cover.
Install the seat adjusters to the seat.
Connect the electrical connectors, if necessary.
Install the seat adjuster retainers.
Install the seat. Refer to Seat Replacement
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Document ID: 528624
Page 1 of 3
Front Seat Lumbar Support Replacement (AM1,AM2)

Removal Procedure
1. Remove the seat with the aid from an assistant. Refer to one of the following procedures:
Seat Replacement
Seat Replacement
2. Place the seat upside down on a clean, protected surface.
3. Remove the adjuster bolts (2) and the adjuster assembly (4).
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Page 2 of 3
4. Remove the lumbar knob (1). Refer to Lumbar Support Knob Replacement .
5. Remove the lumbar adjuster.
1. Install the lumbar adjuster.
2. Install the lumbar knob (1). Refer to Lumbar Support Knob Replacement .
3. Install the seat adjuster assembly (4) and bolts (2).

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF
or LOCK
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4. Install the adjuster assembly bolts.
Tighten
Tighten the adjuster assembly bolts to 24 Nm (17 lb ft).
5. With the aid from an assistant, install the seat. Refer to Seat Replacement .
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Document ID: 513743
Page 1 of 2
Lumbar Support Knob Replacement (AM1,AM2)

Removal Procedure
1. Carefully pull outward the manual lumbar knob (1), in order to remove.
2. Remove the lumbar knob.
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1. Align the lumbar knob (1) and index the slot with the actuator shaft.
2. Carefully push inward the knob in order to secure the knob, to the actuator shaft.
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Document ID: 528754
Page 1 of 3
Front Seat Adjuster Replacement

Removal Procedure
1. Remove the front seat. Refer to Seat Replacement .

2. Place the seat upside down on a clean protected surface.
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Document ID: 528754
Page 2 of 3
3. Remove the adjuster to seat cushion frame bolts (2).

4. Remove the adjuster assembly (4).
1. Install the seat adjuster assembly (4) to the seat cushion frame.
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Document ID: 528754
Page 3 of 3
2. Install the seat adjuster bolts (2).
Tighten
3. Install the front seat. Refer to Seat Replacement .
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2/7/2011
Document ID: 415261
Page 1 of 2
Front Seat Adjuster Motor Replacement

Removal Procedure
2.
3.
4.
5.
6.
Place the seat upside down on a clean, protected surface.

Remove the drive cables from the motor.
Use the drill bit in order to remove the retaining rivets.
Remove the motor from the motor support (2).
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1.
2.
3.
4.
5.
Page 2 of 2
Install the motor to the motor support (2).

Secure the motor with a nut (1) and a bolt.
Install the drive cables to the motor.
Connect the electrical connectors to the motor.
Install the seat. Refer to Seat Replacement .
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Document ID: 299738
Page 1 of 1
Seat Horizontal and Vertical Drive Cable Replacement
Important: Remove the nut (1) that secures the motor support bracket in order to gain access to
the inboard cable connector at the motor or the outboard rear vertical gear nut.
Disconnect the cables by squeezing the oblong connectors at the following components:
The motors
The adjuster drives
The position sensors, if equipped.
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Document ID: 299739
Page 1 of 2
Driver or Passenger Seat Head Restraint Replacement

Removal Procedure
1. Raise the head restraint (1) to the full up position.

2. Disengage the lock by inserting a small-pointed tool or a medium sized paper clip into the
hole in the front of the headrest guide.
3. Pull upward the head restraint out of the guide while applying pressure to the locks with the
small-pointed tool.
4. Remove the head restraint assembly (1).
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1. Insert the head restraint into the head restraint guides (1).
Push the head restraint to the full-down position.
2. Verify that the lock springs are engaged by pulling upward on the head restraint.
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Document ID: 299741
Page 1 of 3
Front Seat Armrest Replacement (Storage)

Removal Procedure

2. Remove the HVAC duct (3) at the armrest, if applicable.
3. Remove the hog rings (3) from the seat cushion flap (2) on the underside of the seat
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The 4 nuts (1)

The armrest

The 4 nuts (1)
The armrest (1)
2. Install the hog rings (3) to the seat cushion flap (2) on the underside of the seat.
3. Install the HVAC duct (3) at the armrest, if applicable.
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Document ID: 299741
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4. Install the seat. Refer to Seat Replacement .
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Document ID: 321594
Page 1 of 2
Front Seat Armrest Replacement (Center with foam)

Removal Procedure
1. Remove the seat from the vehicle.

2. Remove the fasteners (3) that attach the armrest (1).
3. Remove the armrest (1).
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1. Install the armrest (1).

2. Install the fasteners (3) to the armrest (1).
3. Install the seat into the vehicle.
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2/7/2011
Document ID: 299742
Page 1 of 4
Rear Seat Cushion Replacement

Removal Procedure
1. Push the lower forward edge of the seat cushion (1) rearward.
2. Lift upward and pull forward on the seat cushion frame in order to disengage the cushion
frame wires (3) from the retainers (2) on the rear seat pan.
3. If the cushion is difficult to disengage from the seat pan retainers, grasp the lower edge of
the seat cushion at the retainer location on one side of the seat. Exert enough rearward
pressure in order to disengage the seat from the retainers.
4. Place the seat upside down on a clean surface.
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Document ID: 299742
Page 2 of 4
5. Remove the hog rings (2) on the cushion frame.

6. Turn the seat over. Disengage the hook-and-loop (1) under the top surface of the cover.
7. Remove the cover.
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Document ID: 299742
Page 3 of 4
1. Install the cover over the pad. Align the locating holes (3) in the cover to the work lines (4)
in the pad.
2. Engage the hook-and-loop (1).
3. Install the hog rings (2).
Work outward toward the corners until you have installed all of the hog rings.
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Document ID: 299742
Page 4 of 4
4. Carefully lift the cushion into the body. Do not damage the adjacent trim.
5. Position the rear edge of the cushion under the rear seat back while you position the seat
belt straps.
6. Align the frame wire offsets (3) at the front of the seat cushion frame with the retainers (2)
on the floor pan. Push the seat cushion rearward until the offsets engage in the retainers.
Fully engage the retainers by pressing down and pulling the cushion forward.
7. If the cushion is difficult to engage to the seat pan retainers, grasp the lower edge of the
seat cushion at the retainer location on one side of the seat. Exert enough rearward pressure
in order to engage the seat into the retainers.
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2/7/2011
Document ID: 299743
Page 1 of 4
Rear Seat Back Cushion Replacement

Removal Procedure
1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement .
2. Remove the following components from the inner studs:

The lap belt nuts (3)
The lap belts (4)
3. Remove the push-nuts from the outer studs.
4. Remove the rear seat back from the vehicle.
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Document ID: 299743
Page 2 of 4
5. Perform the following steps in order to remove the armrest (6), if applicable:
5.1. Remove the bolts (5) from the seat back.
5.2. Remove the pivot screws (4).
5.3. Remove the armrest (6).
6. Remove the hog rings (7) from the seat back frame
7. Disengage the hook and loop strips (2).
8. Remove the cover (1).
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Document ID: 299743
Page 3 of 4
1. Install the cover (1) over the pad (3). Align the locating holes (8) in the cover to the work
lines (9) in the pad.
2. Install the hog rings (7).
Work outward toward the corners until you have installed all of the hog rings.
3. Turn over the seat.
Engage the hook and loop strips (2).
4. Perform the following steps in order to install the armrest (6), if applicable:
4.1. Secure the armrest (6) to the support with pivot screws (4).
4.2. Attach the armrest (6) to the seat back with bolts (5).
5. Install the rear seat back.
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Document ID: 299743
Page 4 of 4
6. Install the lap belt nuts (3).
Tighten
Tighten the lap belt nuts to 35 Nm (25 lb ft).
7. Verify that the shoulder belts (4) operate freely.
8. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement .
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2/7/2011
Document ID: 396712
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Restraints | SIR | Specifications |
Document ID: 396712

Specification
Application
Metric English
Inflatable Restraint Front End Discriminating Sensor Fasteners
12 Nm
9 lb ft
Inflatable Restraint IP Module Bolts (Buick)
11 Nm
94 lb in
Inflatable Restraint IP Module Nuts (Buick)
10 Nm
84 lb in
Inflatable Restraint IP Module Fasteners (Oldsmobile)
16 Nm
12 lb ft
Inflatable Restraint IP Module Bolts (Pontiac)
2 Nm
17 lb in
Inflatable Restraint IP Module Nuts (Pontiac)
10 Nm
84 lb in
Inflatable Restraint Sensing and Diagnostic Module (SDM) Fasteners
9 Nm
80 lb in
Inflatable Restraint Steering Wheel Module Screws
3 Nm
27 lb in
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Document ID: 183846
Page 1 of 1
Document ID: 183846
Scan Tool Data List

The scan tool used provides the following capabilities:
Read the data list
Read current and history diagnostic trouble codes (DTCs)
Clear the DTCs after a repair is completed
Before attempting to communicate with the SIR system, ensure that the scan tool contains the
latest software. Connect the scan tool to the data link connector (DLC) and turn the ignition switch
to the RUN position. The scan tool reads the serial data sent from the inflatable restraint sensing
and diagnostic module (SDM) serial data output terminal 5 to the DLC terminal 9. The following
table shows the typical values of the data displays under the following conditions:
The ignition switch is in the RUN position.
The engine is OFF.
The driver seatbelt is buckled.
Data List
Description
Typical
Value
Ignition
Ignition 1 power feed
Lamp Driver
Warning lamp control method (hard wired lamp)
Driver Resistance
Driver deployment loop resistance
2.6 ohms
Passenger
Resistance
Passenger deployment loop resistance
2.2 ohms
Driver Senselo
Driver low terminal voltage
Passenger Senselo Passenger low terminal voltage
12 V
Internal
4.1 V
4.1 V
Driver VDIF
Voltage difference between driver high and driver low

terminals
4-8 mV
Passenger VDIF
Voltage difference between passenger high and passenger

low terminals
4-8 mV
Warning Lamp ON
Continuous warning lamp ON time
Warning Lamp
Control
Warning lamp state commanded by the SDM (On/Off)
Lamp Driver
Feedback
Warning lamp state detected by the SDM (Active/Inactive)
Inactive
Warning Lamp
Cycles
Ignition cycles of the current warning lamp state
0 - 125
Cycles
Driver Seatbelt
Driver seatbelt status (Buckled/Unbuckled)
Buckled
0 - 182 Hrs
Off
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Document ID: 198964
Scan Tool Data Definitions

The Scan Tool Data Definitions contain a short description of all SIR related parameters available
on the scan tool. The list is in alphabetical order.
ADS: The scan tool displays Active or Inactive. The inflatable restraint forward discriminating
sensor sends an Active signal to the SDM in order to show the SDM's state of readiness.
Coil Resistance: The scan tool displays 0-5 ohms. The SDM performs the resistance measurement
test once each ignition cycle and verifies the SIR Contact Coil resistances are within the normal
ranges.
Driver Bag Energy Reserve: The scan tool displays 0-25 volts. The SDM measures the internal
reserve voltage available in order to activate the driver side deployment loop.
Driver Resistance: The scan tool displays 0-6.3 ohms. The SDM performs the resistance
measurement test once each ignition cycle.After the resistance check, the SDM verifies the Ignition
1 voltage and the 23-volt loop reserve are within the normal ranges. At that time, the SDM
supplies a constant current to the driver deployment loop. The SDM measures the voltage drop
across the deployment loop and converts the measured voltage value to a deployment loop
resistance value.
Driver Seat Belt: The scan tool displays Buckled or Unbuckled. The signal from the drivers seatbelt switch indicates that the seat belt is buckled.
Driver Senselo: The scan tool displays 0-20 volts. The SDM measures the low-side terminal
voltage of the driver deployment loop, and the scan tool displays this voltage as Driver Senselo.
Driver VDIF: The scan tool displays 0-500 mV. The SDM measures the voltage difference between
driver high and driver low circuits, and the scan tool displays this voltage difference as Driver VDIF.
Ignition: The scan tool displays 0-25.5 volts. The ignition represents the system voltage which is
measured by the SDM at the SDM ignition feed.
Lamp Driver Feedback: The scan tool displays Active or Inactive. The warning lamp state is
detected by the SDM.
Passenger Bag Energy Reserve: The scan tool displays 0-25 volts. The SDM measures the
internal reserve voltage available in order to activate the passenger side deployment loop.
Passenger Resistance: The scan tool displays 0-6.3 ohms. The SDM performs the resistance
measurement test once each ignition cycle and verifies the Ignition 1 voltage and 23-volt loop
reserve are within the normal ranges. At that time, the SDM supplies a constant current to the
passenger deployment loop. The SDM measures the voltage drop across the deployment loop and
converts the measured voltage value to a resistance value of the passenger deployment loop.
Passenger Senselo: The scan tool displays 0-20 volts. The SDM measures the low-side terminal
voltage of the passenger deployment loop, and the scan tool displays this voltage as Passenger
Senselo.
Passenger VDIF: The scan tool displays 0-500 mV. The SDM measures the voltage difference
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General low
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Corporation.
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between passenger high and
passenger
circuits
and displays
voltage difference as
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Document ID: 198964
Page 2 of 2
Passenger VDIF.
SIR System Type: The scan tool displays the type of deployment loops.
Warning Lamp Control: The scan tool displays ON or OFF. The warning lamp state is commanded
by the SDM.
Warning Lamp Cycles: The scan tool displays 0-125 cycles. The ignition cycles of the current
warning lamp state.
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Document ID: 393711
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Restraints | SIR |
Cell 47
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Document ID: 401767
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Cell 47: AIR BAG Indicator
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Document ID: 231244
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Engine Compartment, Center Front
(1) Inflatable Restraint Front End Discriminating Sensor
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Document ID: 231242
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Passenger Compartment, RH Front

(2) Inflatable Restraint IP Module connector
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Document ID: 343401
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Passenger Compartment, Under the Right Hand Front Seat
(1) S302
(2) S303
(3) G301
(4) Inflatable Restraint Sensing and Diagnostic Module (SDM)
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Passenger Compartment, Steering Column
(1) C202
(2) Ignition Switch
(3) Shift Interlock Actuator (Hidden)
(4) Horn Switch
(5) Inflatable Restraint Steering Wheel Module
(6) Steering Wheel Controls LH and RH
(7) Inflatable Restraint Steering Wheel Module Coil
(8) Headlamp Dimmer Switch
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Document ID: 396724
Page 1 of 3
SIR Connector End Views

Table 1:
Inflatable Restraint Front End Discriminating Sensor
Table 2:
Inflatable Restraint IP Module
Table 3:
Inflatable Restraint Sensing and Diagnostic Module (SDM)
Table 4:
Inflatable Restraint Steering Wheel Module Coil
12084302
2 Way F Metri-Pack 280 Series Sealed (YEL)
Pin
Wire Color
Circuit No.
Function
BLK/WHT
1751
Ground
YEL
1834
SIR Forward Sensor Signal
Inflatable Restraint IP Module
12110288
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2 Way M Metri-Pack 280 Series (YEL)

Pin
Wire Color
Circuit No.
WHT/BLK
1403
Passenger High
DK GRN/WHT
1404
Passenger Low
Function
Inflatable Restraint Sensing and Diagnostic Module (SDM)
12160333
12 Way F Micro-Pack 100 Series (YEL)
Pin
Wire Color
Circuit No.
Function
WHT/BLK
1403
WHT
347
SIR Inflator Feed - Driver High
DK GRN
348
SIR Inflator Output - Driver Low
DK GRN/WHT
1404
TAN
800
BLK/WHT
1751
BRN
358
SIR Indicator Lamp Output
BLK/WHT
238
Seat Belt Switch Signal
YEL
1834
SIR Forward Sensor Signal
10
YEL
1139
Ignition 1
11-12
--
--
Not Used
SIR Inflator Feed - Passenger High
SIR Inflator Output - Passenger Low

Serial Data Signal (UART)
Ground
Inflatable Restraint Steering Wheel Module Coil
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12092851
2 Way M Metri-Pack 280 Series (YEL)
Pin
Wire Color
Circuit No.
WHT
347
Driver High
DK GRN
348
Driver Low
Function
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Document ID: 98144
Page 1 of 1
SIR Service Precautions

Caution: When you are performing service on or near the SIR components or the SIR wiring, you
must disable the SIR system. Refer to Disabling the SIR System. Failure to follow the correct
procedure could cause air bag deployment, personal injury, or unnecessary SIR system repairs.
The inflatable restraint sensing and diagnostic module (SDM) maintains a reserve energy supply.
The reserve energy supply provides deployment power for the air bags. Deployment power is
available for as much as 10 minutes after disconnecting the vehicle power by any of the following
methods:
Turn the ignition switch to the OFF position.
Remove the fuse that provides power to the SDM.
Disconnect the vehicle battery from the vehicle electrical system.
Disabling the SIR system prevents deploying of the air bags from the reserve energy supply power.
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Disabling the SIR System
1. Turn the steering wheel in order to ensure that the vehicle's wheels point straight ahead.
3. Remove the key from the ignition switch.
Important: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the
AIR BAG warning lamp illuminates. This is normal operation, and does not indicate an SIR
system malfunction.
4. Remove the AIR BAG Fuse from the IP fuse block.
5. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement Left Side in Instrument Panel, Gauges and Console.
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6. Remove the connector position assurance (CPA) (3) from the inflatable restraint steering
wheel yellow 2-way connector (1). The 2-way connector is located at the base of the steering
column.
7. Disconnect the inflatable restraint steering wheel yellow 2-way connector (1,3). This
connector is located at the base of the steering column.
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8. Remove the right sound insulator (3). Refer to Instrument Panel Insulator Panel Replacement
- Right Side in Instrument Panel, Gauges and Console.
9. Locate the inflatable restraint IP module yellow 2-way connector (2) (Pontiac).
10. Locate the inflatable restraint IP module yellow 2-way connector (2) (Buick).
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11. Locate the inflatable restraint IP module yellow 2-way connector (3) (Oldsmobile).
12. Remove the connector position assurance (CPA) (2) from the inflatable restraint IP module
yellow 2-way connector (1). The connector is located above the right sound insulator.
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13. Disconnect the inflatable restraint IP module yellow 2-way connector (2) from the harness
connector (1). The connector is located above the right sound insulator.
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Enabling the SIR System
1. Remove the key from the ignition switch.

2. Connect the inflatable restraint IP module yellow 2-way connector (2). The connector is
located above the right sound insulator.
3. Attach the inflatable restraint IP module yellow 2-way connector (2) to the IP sound insulator
(1) (Pontiac).
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4. Attach the inflatable restraint IP module yellow 2-way connector to the IP (2) (Buick).
5. Attach the inflatable restraint IP module yellow 2-way connector (3) to the IP sound insulator
(1) (Oldsmobile).
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6. Install the connector position assurance (CPA) (2) to the inflatable restraint IP module yellow
2-way connector (1). The connector is located above the right sound insulator.
7. Install the right sound insulator. Refer to Instrument Panel Insulator Panel Replacement Right Side in Instrument Panel, Gauges, and Console.
8. Connect the inflatable restraint steering wheel yellow 2-way connector (1,3). The connector
is located near the base of the steering column.
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9. Install the connector position assurance (CPA) (3) to the inflatable restraint steering wheel
yellow 2-way connector (1). The connector is located near the base of the steering column.
10. Install the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left
Side in Instrument Panel, Gauges, and Console.
11. Install the AIR BAG fuse in the IP fuse block.
Important: Ensure that you remain a safe distance from both of the air bags.
12. Turn the ignition switch to the RUN position. The following actions should occur:
12.1. The AIR BAG warning lamp will flash 7 times.
12.2. The AIR BAG warning lamp will then turn OFF.
13. Perform the SIR diagnostic system check. Refer to SIR Diagnostic System Check .
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General Service Instructions

Do not expose the inflator modules to temperatures above 65C (150F).
Verify the correct replacement part number. Do not substitute a component from a different
vehicle.
Do not repair any of the following components. Service the following components by
replacement only:
- The inflatable restraint sensing and diagnostic module (SDM)
- The inflatable restraint IP (inflator) module
- The inflatable restraint steering wheel (inflator) module
- The inflatable restraint steering wheel module coil
- The inflatable restraint front end discriminating sensor
Use only original GM replacement parts available from your authorized GM dealer. Do not use
salvaged parts for repairs to the SIR system.
Do not install any of the following components if the components have been dropped from a
height of 91 centimeters (3 feet) or greater. Discard the component:
- The inflatable restraint sensing and diagnostic module (SDM)
- The inflatable restraint IP (inflator) module
- The inflatable restraint steering wheel (inflator) module
- The inflatable restraint steering wheel module coil
- The inflatable restraint front end discriminating sensor
When you replace the SDM, verify that the following conditions are met:
- The mounting surface is clean.
- The arrow on the module points toward the front of the vehicle.
- The module is flat on the mounting surface, parallel to the vehicle datum line.
- The module fasteners are installed and tightened as specified.
In order to avoid setting false diagnostic trouble codes, only apply power to the SIR system
when 1 of the following 2 conditions is met:
- All SIR system components are properly mounted and electrically connected.
- A diagnostic procedure directs you to apply power.
Begin diagnosis of malfunctions with the SIR Diagnostic System Check. Perform the SIR
Diagnostic System Check in order to verify the following items:
- The proper operation of the AIR BAG warning lamp.
- Communication with the SDM through the serial data line.
- The presence or absence of diagnostic trouble codes.
- Whether additional diagnosis is required and where the information resides.
Not beginning with the SIR Diagnostic System Check may result the following conditions:
- Extended diagnostic time
- Incorrect diagnosis
- Unneeded parts replacement
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Document ID: 396900
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Inflatable Restraint Sensing and Diagnostic Module

Replacement
Removal Procedure
CAUTION: Be careful when you handle a sensing and diagnostic module (SDM). Do not
strike or jolt the SDM. Before applying power to the SDM:
Remove any dirt, grease, etc. from the mounting surface
Position the SDM horizontally on the mounting surface
Point the arrow on the SDM toward the front of the vehicle
Tighten all of the SDM fasteners and SDM bracket fasteners to the specified torque
value
Failure to follow the correct procedure could cause air bag deployment, personal injury, or
unnecessary SIR system repairs.
1. Disable the SIR system. Refer to Disabling the SIR System .
2. Remove the passenger front seat. Refer to Seat Replacement in Seats.
3. Remove the right carpet retainer. Refer to Front Floor Mat/Carpet Replacement in Interior
Trim.
4. Lift up the carpet and insulation in order to access the inflatable restraint sensing and
diagnostic module (SDM).
5. Remove the connector position assurance (CPA) (3) from the SDM harness connector (2).
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6. Disconnect the SDM harness connector (2) from the SDM (1).
7. Remove the SDM (3) mounting fasteners (1).

8. Remove the SDM (3) from the floor sheet metal (2).
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1. Install the SDM (3) to the floor sheet metal (2).

2. Install the SDM mounting fasteners (1).
Tighten
Tighten fasteners to 9 Nm (80 lb in).
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3. Install the SDM harness connector (2) to the SDM (1).
4. Install the connector position assurance (CPA) (3) to the SDM harness (2) connector.
5. Install the right carpet retainer. Refer to Front Floor Mat/Carpet Replacement in Interior
Trim.
6. Install the passenger front seat. Refer to Seat Replacement in Seats.
Important: The AIR BAG indicator may remain ON after the SDM has been replaced.
DTC B1001 may set requiring the SDM part number to be set in multiple modules. If the
indicator remains ON after enabling the SIR system, perform the diagnostic system check
and follow the steps thoroughly to ensure that the SDM is set properly.
7. Enable the SIR system. Refer to Enabling the SIR System .
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Document ID: 396906
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Instrument Panel Inflatable Restraint Module

Replacement (Buick)
Removal Procedure
Caution: When you are carrying an undeployed inflator module:
Do not carry the inflator module by the wires or connector on the inflator module
Make sure the bag opening points away from you
When you are storing an undeployed inflator module, make sure the bag opening points
away from the surface on which the inflator module rests. When you are storing a steering
column, do not rest the column with the bag opening facing down and the column vertical.
Provide free space for the air bag to expand in case of an accidental deployment. Otherwise,
3. Remove the inflatable restraint IP module mounting fasteners (2,3).
4. Remove the inflatable restraint IP module (4) from the IP (1).
5. Fully deploy the module before disposal. If the module was replaced under warranty, fully
deploy and dispose of the module after the required retention period. Refer to Inflator Module
Handling, Shipping, and Scrapping .
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1. Route the pigtail (5) down through the IP (1).
2. Slide the inflatable restraint IP module (4) into the IP opening (1).
Important: Install the top fasteners first.
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3. Install all of the inflatable restraint IP module mounting fasteners.

Tighten
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Replacement (Oldsmobile)
Removal Procedure
2. Remove the IP upper trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in
3. Remove the inflatable restraint IP module mounting fasteners (3).
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1. Route the pigtail (4) down through the IP (2).

2. Slide the inflatable restraint IP module (1) into the IP opening.
Tighten
Tighten fasteners to 16 Nm (12 lb ft).
4. Install the upper IP trim pad. Refer to Instrument Panel Upper Trim Pad Replacement in
Instrument Panel, Gauges, and Console.
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Page 1 of 2

Replacement (Pontiac)
Removal Procedure
Gauges, and Console.
3. Remove the inflatable restraint IP module mounting bolts (7,8).
4. Remove the inflatable restraint IP module mounting nuts (6,5,4,3,2,1).
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1. Slide the inflatable restraint IP module (4) into the IP opening.

Tighten
Tighten the nuts, in the proper order (1,2,3,4,5,6) to 10 Nm (84 lb in).
Tighten the bolts, in the proper order (7,8) to 2 Nm (17 lb in).
3. Install the IP Assembly. Refer to Instrument Panel Assembly Removal in Instrument Panel,
Gauges, and Console.
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Replacement
Removal Procedure
Caution: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before applying
power to a sensor:
Remove any dirt, grease, etc. from the mounting surface.
Position the sensor horizontally on the mounting surface.
Point the arrow on the sensor toward the front of the vehicle.
Tighten all of the sensor fasteners and sensor bracket fasteners to the specified torque value.
Failure to follow the correct procedure could cause air bag deployment, personal injury, or
unnecessary SIR system repairs.

2. Remove the connector position assurance (CPA) (1) from the inflatable restraint front end
discriminating sensor harness connector (2).
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3. Disconnect the inflatable restraint front end discriminating sensor harness connector from the
pigtail connector.
4. Remove the inflatable restraint front end discriminating sensor mounting fasteners (1).
5. Remove the inflatable restraint front end discriminating sensor (2) from the front end
discriminating sensor bracket (4).
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1. Install the inflatable restraint front end discriminating sensor (2) to the front end
discriminating sensor bracket (4).
2. Install the inflatable restraint front end discriminating sensor mounting fasteners (1).
Tighten
Tighten fastener to 12 Nm (9 lb ft).
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3. Connect the inflatable restraint front end discriminating sensor harness connector to the
pigtail connector.
4. Install the connector position assurance (CPA) (1) to the inflatable restraint front end
discriminating sensor harness connector (2).
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Steering Wheel Inflatable Restraint Module

Replacement
Removal Procedure
1. Disable the SIR System. Refer to Disabling the SIR System .
2. Remove the 2 screws (9) at the back of the steering wheel (1).
Important: Note the wire routing for assembly reference.
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3.
4.
5.
6.
7.
8.
9.
10.
Page 2 of 3
Position the inflator module (3) in order to gain access to the wire connectors.
Push in and rotate the horn contact lead (6) counterclockwise.
Remove the horn contact lead (6) from the steering column horn tower.
Remove the horn contact lead (6).
Remove the retainer (CPA) (10) from the SIR wiring connector.
Remove the SIR wiring connector from the inflatable restraint steering wheel module (3).
Disconnect the steering wheel control switch connector (7).
Remove the inflatable restraint steering wheel module (3).
1. Connect the steering wheel switch connector, if equipped.
2.
3.
4.
5.
6.
7.
Install the retainer (CPA) (10) to the SIR wiring connector.

Route the horn contact lead (6) to the steering column horn tower.
Push the lead (6) into the horn tower.
Rotate the lead (6) clockwise to locked position.
Install the horn ground to lead (6).
Install the SIR connector and retainer (CPA).
Important: Do not pinch any wires.
8. Install the inflatable restraint steering wheel module (3) to the steering wheel (1).
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First install the top surface of the module (3) in order to ease assembly and fit.
9. Install the 2 screws (9) through the back of the steering wheel (1) to the inflator module (3).
Tighten
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Steering Wheel Inflatable Restraint Module Coil

Replacement
Removal Procedure

Wheel
3. Remove the steering wheel inflator module (3). Refer to Inflatable Restraint Steering
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Module Replacement .
4. Remove the steering wheel retaining nut (2).
5. Remove the steering wheel (1) from the steering column shaft. Refer to Steering Wheel
Replacement .
Important: The column must be in the 12 o'clock position.

To align the steering shaft assembly to the 12 o'clock position. Turn the key to the off/lock
position. Pull the key out and turn the steering shaft until you hear a click.
6. The turn signal switch assembly must be in the UP position.
7. Refer to Inflatable Restraint Steering Wheel Module Coil Disassemble - Off Vehicle in Steering
for complete procedure.
8. Pop the wire harness assembly out of the wire harness strap (1).
9. Check steering column for accident damage. Refer to Steering Column Accident Damage
Inspection - Off Vehicle in Steering.
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10. Remove the SIR connector (1) from the fused jumper assembly connector (2).
11. Remove the retaining ring.
12. Remove the wire protector.

13. Remove the SIR coil assembly.
14. To remove the SIR coil assembly completely refer to the upper tilt head component assembly
Turn Signal Cancel Cam and Upper Bearing Inner Race - Disassemble - Off Vehicle in
Steering.
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1. To install the inflatable restraint steering wheel module coil:

Make sure that the wheels are straight ahead.
Align the block tooth and the centering mark on the race and upper shaft assembly (1) at
the 12 o'clock position.
2. The new SIR coil assembly will come pre-centered.

3. If installing the existing SIR coil assembly, proceed to the next step.
4. Follow the instructions on the notice (1) of the SIR coil assembly.
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Important: The column must be in the 12 o'clock position.

5.
6.
7.
8.
Align the steering column to the 12 o'clock position.

Install the hanging SIR coil assembly onto the race and upper shaft assembly.
The new SIR coil assembly will come precentered. Once installed, pull the tab and remove.
If the SIR coil assembly is completely off refer to the upper tilt head component assembly
Turn Signal Cancel Cam and Upper Bearing Inner Race - Assemble - Off Vehicle in Steering.
9. Install the wire protector into the support bracket.
10. Install the retaining ring.
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11. Install the SIR coil assembly connector (1) to the fused jumper assembly connector (2).
12. Put the wire harness assembly into the wire harness strap (1). Refer to Inflatable Restraint
Steering Wheel Module Coil Assemble - Off Vehicle for complete installation procedure located
in Steering.
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13. Install the steering wheel (1). Refer to Steering Wheel Replacement in Steering.
14. Install the steering wheel inflator module (3). Refer to Inflatable Restraint Steering Wheel
Module Replacement .
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Document ID: 99657
Page 1 of 6
Wiring Repair
The supplemental inflatable restraint (SIR) system requires special wiring repair procedures due to
the sensitive nature of the circuitry. Follow the specific procedures and instructions when working
with the SIR system wiring, and the wiring components (such as connectors and terminals).
Important: Do not use the terminals in the kit in order to replace damaged SIR system terminals
unless specifically indicated by the terminal package.
Tools Required
J-38125 Terminal Repair Kit
The tool kit J-38125 contains the following items:
Special sealed splices - in order to repair the SIR system wiring
A wire stripping tool
A special crimping tool
A heat torch
An instruction manual
The sealed splices has the following 2 critical features:
A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains
a sealing adhesive inside.
A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive,
low energy circuits.
The J-38125 also serves as a generic terminal repair kit. The kit contains the following items:
A large sampling of common GM electrical terminals
The correct tools in order to attach the terminals to wires
The correct tools in order to remove the terminals from connectors
SIR Connector (Plastic Body and Terminal Metal Pin)

Repair
Use the connector repair assembly packs in order to repair the damaged SIR wire harness
connectors and the terminals. Do not use the connector repair assembly pack in order to repair the
pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in
order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is
color keyed in order to match the splices from the J-38125 . You must use the splice crimping tool
in order to apply these splices.
The terminals in the SIR system are made of a special metal. This metal provides the necessary
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contact integrity for the sensitive, low energy circuits. These terminals are only available in the
connector repair assembly packs. Do not substitute any other terminals for those in the assembly
packs.
If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness
connector, use 1 of the following 2 components in order to replace the SDM harness connector:
The SDM harness connector pigtail assembly
The SDM harness connector replacement kit
If the individual terminals are damaged on any other SIR connection, use the appropriate
connector repair assembly pack in order to replace the entire connection. Replace the entire SIR
wiring harness, if needed, in order to maintain SIR circuit integrity.
SIR Wire Pigtail Repair

Important: Do not make wire, connector, or terminal repairs on components with wire pigtails.
A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring
pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint
steering wheel module coil is an example of a pigtail component.
SIR Wire Repair

Tools Required
J-38125 Terminal Repair Kit
Important: Refer to Wiring Repairs in Wiring Systems in order to determine the correct wire
size for the circuit you are repairing. You must obtain this information in order to ensure
circuit integrity.
1. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire
of the same gauge size (0.5 mm (.020 in), 0.8 mm (.031 in), 1.0 mm (.039 in) etc.). Use the
sealed splices and splice crimping tool from the J-38125 . Use the following wiring repair
procedures in order to ensure the integrity of the sealed splice.
Important: You must perform the following procedures in the listed order. Repeat the
procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire
strands intact.
2. Open the harness by removing any tape:
Use a sewing seam ripper (available from sewing supply stores) in order to cut open the
harness in order to avoid wire insulation damage.
Use the crimp and sealed splice sleeves on all types of insulation except tefzel and
coaxial.
Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires
coming together.
3. Cut as little wire off the harness as possible. You may need the extra length of wire in order
to change the location of a splice.
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Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other
splices, harness branches, or connectors.
4. Strip the insulation:
When adding a length of wire to the existing harness, use the same size wire as the
original wire.
Perform one of the following items in order to find the correct wire size:
- Find the wire on the schematic and convert the metric size to the equivalent AWG size.
- Use an AWG wire gauge.
- If you are unsure of the wire size, begin with the largest opening in the wire stripper and
work down until achieving a clean strip of the insulation.
Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
If the wire is damaged, repeat this procedure after removing the damaged section.
5. Select the proper sealed splice sleeve according to wire size.
Refer to the following table for color coding of the splice sleeves, and the crimp tool nests.
6. Use the Splice Crimp Tool from the J-38125 in order to position the splice sleeve in the
proper color nest of the Splice Crimp Tool.
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7. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the
barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to
prevent the wire (1) from going further. Close the hand crimper handles slightly in order to
firmly hold the splice sleeve in the proper nest.
8. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
9. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice
sleeve. Repeat steps 4 and 5 for the opposite end of the splice.
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10. Using the heat torch, apply heat to the crimped area of the barrel.
11. Gradually move the heat barrel to the open end of the tubing:
The tubing will shrink completely as the heat is moved along the insulation.
A small amount of sealant will come out of the end of the tubing when sufficient shrinkage
is achieved.
Crimp and Seal Splice Table

Splice Sleeve Color
Crimp Tool Nest Color
Wire Gauge mm / (AWG)
Salmon (yellow-pink)
Red (1)
0.5-0.8 / (18-20)
Blue
Blue (2)
1.0-2.0 / (14-16)
Yellow
Yellow (3)
3.0-5.0 / (10-12)
SIR System Wire Splice Repair

Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment
splices (3 wires or more) in the SIR wiring harness. Carefully follow the instructions included in the
kit for proper splice clip application.
Connector Position Assurance (CPA)

The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of
all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate
apart. You must have the CPA in place in order to ensure good contact between the SIR mating
terminals.
Terminal Position Assurance (TPA)

The terminal position assurance (TPA) insert resembles the plastic combs used in the control
module connectors. The TPA keeps the terminal securely seated in the connector body. Do
not
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remove the TPA from the connector body unless you remove a terminal for replacement.
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Repairs and Inspections Required After a Collision

Accident With or Without Air Bag Deployment -Component Inspections
CAUTION: Proper operation of the Supplemental Inflatable Restraint (SIR) sensing system
requires that any repairs to the vehicle structure return the vehicle structure to the original
production configuration. Not properly repairing the vehicle structure could cause non-deployment
of the air bag(s) in a frontal collision or deployment of the air bag(s) for conditions less severe than
intended.
After any collision, inspect the following components as indicated. If you detect any damage,
replace the component. If you detect any damage to the mounting points or mounting hardware,
repair the component or replace the hardware as needed:
Steering column
Perform the steering column accident damage checking procedures. Refer to Steering.
Inflatable restraint front end discriminating sensor
Determine the need for replacement based on the following Sensor Replacement Guidelines.
IP Knee Bolsters
Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage.
IP brackets, braces, etc.
Inspect for bending, twisting, buckling, or any other type of damage.
IP steering column reinforcement plate
Inspect for bending, twisting, buckling, or any other type of damage.
Seat Belts
Perform the seat belt operational and functional checks. Refer to Operational and Functional
Checks in Seat Belts.
Accident With Air Bag Deployment -- Component

Replacement and Inspections
After a collision involving air bag deployment, replace the following components. If you detect any
damage to the mounting points or mounting hardware, repair or replace the mounting points and
mounting hardware as needed:
Inflatable restraint IP (inflator) module
Inflatable restraint steering wheel (inflator) module
Inflatable restraint sensing and diagnostic module (SDM)
After a collision involving air bag deployment, inspect the inflatable restraint steering wheel module
coil and the coil wiring pigtail for melting, scorching, or other damage due to excessive heat.
Perform this component inspection in addition to the inspections indicated above in Accident With
Motorsany
Corporation.
All replace
rights reserved.
2011IfGeneral
or Without Air Bag Deployment.
you detect
damage,
the component. If youtomsn048@gmail.com
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any damage to the mounting points or mounting hardware, repair the component or replace the
hardware as needed.
Sensor Replacement Guidelines

The SIR sensor replacement policy requires replacing the sensors in the area of accident damage.
The area of accident damage is defined as the portion of the vehicle that is crushed, bent, or
damaged due to a collision. If the vehicle has a SIR sensor mounted forward of the radiator,
replace the SIR sensor.
Replace the sensor even if the air bags have not deployed.
Replace the sensor even if the sensor appears to be undamaged.
Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the
wire insulation, may cause improper operation of the SIR sensing system. Do not try to determine
whether the sensor is undamaged, replace the sensor. Also, replace the sensor if a Diagnostic
Trouble Code (DTC) table indicates a malfunctioning sensor.
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Inflator Module Handling, Shipping, and Scrapping

Live (Undeployed) Inflator Module

When you are storing an undeployed inflator module, make sure the bag opening points away from
the surface on which the inflator module rests. When you are storing a steering column, do not rest
the column with the bag opening facing down and the column vertical. Provide free space for the
air bag to expand in case of an accidental deployment. Otherwise, personal injury may result.
Use special care when handling and storing a live (undeployed) inflator module. An air bag
deployment produces rapid gas generation. This may cause the inflator module, or an object in
front of the inflator module, to jettison through the air in the unlikely event of an accidental
deployment.
Shipping Procedures for Live (Undeployed) Inflator

Modules
Service personnel should refer to the latest Service Bulletins for proper SIR inflator module
shipping procedures.
Scrapping Procedure
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During the course of a vehicle's useful life, you may need to dispose of a live (undeployed) inflator
module. The following information covers the proper procedures for disposing of a live inflator
module. Before you dispose of a live inflator module, you must deploy the inflator module. Do not
dispose of live inflator modules through normal refuse channels.
Caution: In order to prevent accidental deployment of the air bag which could cause personal
injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed
inflator module contains substances that could cause severe illness or personal injury if the sealed
container is damaged during disposal. Use the following deployment procedures to safely dispose of
an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a
violation of federal, state, province, or local laws.
Do not deploy an air bag in the following situations:
If you replace an inflator module under warranty, you may need to return the inflator
module, undeployed, to Delphi Interior & Lighting Systems. Refer to the latest service
bulletin regarding SIR shipping procedures.
If a vehicle is the subject of a Product Liability Report related to the SIR system and is
subject to a Preliminary Investigation (GM-1241), do not alter the SIR system in any
manner. Refer to the latest service bulletin on SIR shipping procedures.
If a vehicle is involved in a campaign affecting the inflator modules, follow the instructions in
the Campaign Service Bulletin for proper SIR handling and shipping procedures.
Deployment Procedures
The inflator module may be deployed inside or outside of the vehicle. The method used depends
upon the final disposition of the vehicle. Review the following procedures in order to determine
which procedure will work best in a given situation.
Deployment Outside of the Vehicle (Inflatable Restraint

Steering Wheel Module)
Tools Required
J 38826 SIR Deployment Harness
When you intend to return the vehicle to service, deploy the inflator modules outside of the vehicle.
Consider the following examples:
Using the SIR Diagnostics, you determine that the inflator module does not function
correctly.
The inflator module is cosmetically damaged, such as a scratch or a rip in the cover.
The inflator module pigtail (if equipped) is damaged.
The inflator module connector is damaged.
An inflator module connector terminal is damaged.
Deployment and disposal of a malfunctioning inflator module is subject to any required retention
period.
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You must follow these inflator module deployment procedures exactly. Always wear safety glasses
during this deployment procedure. Do not remove your safety glasses until the deployed inflator
module is scrapped or shipped. Before performing theses deployment procedures, ensure that you
are familiar with servicing the SIR system. You should also know how to handle the inflator module
properly. Carefully read the procedures before you begin. These procedures require the use of the
following tools:
J 38826 SIR Deployment Harness
The appropriate pigtail adapter
Do not perform the procedure without the J 38826 and the adapter.
CAUTION: When you are deploying an inflator module for disposal, perform the deployment
procedures in the order listed. Failure to follow the procedures in the order listed may result in
personal injury.
Important: This information applies only to inflatable restraint steering wheel modules.
Refer to Deployment Outside of the Vehicle (Inflatable Restraint IP Module) in this section for
information on inflatable restraint IP module scrapping.
1.
2.
3.
4.
Turn the ignition switch to the LOCK position.

Remove the key.
Put on safety glasses.
Inspect the J 38826 and the appropriate pigtail adapter for damage. If either the harness or
the adapter is damaged, obtain a replacement.
5. Short the 2 SIR deployment harness leads together by fully seating one banana plug into the
other, as shown in the figure.
Keep the SIR deployment harness shorted until you are ready to deploy the air bag.
Do not connect the SIR deployment harness to a power source until you are ready to
deploy the air bag.
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6. Connect the appropriate pigtail adapter to the J 38826 .

7. Remove the inflatable restraint steering wheel module from the vehicle. Refer to Inflatable
Restraint Steering Wheel Module Replacement .
8. Remove the horn lead from the back of the inflatable restraint steering wheel module, if
applicable.
9. Remove the redundant steering wheel control lead(s) from the back of the inflatable restraint
steering wheel module, if applicable.
10. Remove all horn buttons and steering wheel control buttons from the inflatable restraint
steering wheel module, if applicable.

11. With the vinyl trim cover facing up and away from the surface, place the inflatable restraint
steering wheel module on a work bench or other surface.
12. Place the inflatable restraint steering wheel module away from all loose or flammable objects.
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13. Clear a space on the ground about 1.85 m (6 ft) in diameter where you intend to deploy the
inflatable restraint steering wheel module. If possible, use a paved, outdoor location free of
activity. Otherwise, use a space free of activity on the shop floor. Provide sufficient
ventilation.
14. Clear all loose or flammable objects from the deployment area.
15. Place the inflatable restraint steering wheel module in the space just cleared, with its vinyl
trim cover facing up.
16. Extend the SIR deployment harness and the pigtail adapter to full length from the inflatable
restraint steering wheel module.
17. Place a power source near the shorted end of the SIR deployment harness. Use a vehicle
battery when available, but always use a power source that meets the following criteria:
12 volts minimum
2 amps minimum
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Important: Firmly seat the pigtail adapter into the inflatable restraint steering wheel module
connector. If you do not do this, the inflator module may not deploy.
18. Connect the inflatable restraint steering wheel module to the pigtail adapter on the SIR
deployment harness.
The deployment harness shall remain shorted until you are ready to deploy the air bag.
Do not connect the SIR deployment harness to a power source until you are ready to
deploy the air bag.
The inflator module will immediately deploy when you connect the power source.
19. Clear the area of all people and loose or flammable objects.
20. Place the inflatable restraint steering wheel module with the vinyl trim cover facing up.
21. Notify all people in the immediate area before you deploy the inflatable restraint steering
wheel module for the following reasons:
An inflatable restraint steering wheel module deployment is very loud.
The deployment may startle any uninformed people in the area.
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22. Separate the 2 banana plugs on the SIR deployment harness.

procedures in the order listed. Failure to follow the procedures in the order listed may result
in personal injury.
Notice: When the air bag deploys, the inflatable restraint steering wheel module may jump
about 30 cm (1 ft) vertically. This is a normal reaction of the inflatable restraint steering
wheel module to the force of the rapid gas expansion inside the air bag.
Notice: The rapid gas expansion involved with deploying an air bag is very loud. Notify all
people in the immediate area that you intend to deploy the inflator module.
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23. Connect the SIR deployment harness wires to the power source. This immediately deploys
the inflatable restraint steering wheel module.
24. Use a vehicle battery when available, but always use a power source that complies to the
following criteria:
12 volts minimum
2 amps minimum
25. Disconnect the SIR deployment harness from the power source.
26. Short the SIR deployment harness leads together by fully seating 1 banana plug into the
other.
27. In the unlikely event that the inflatable restraint steering wheel module did not deploy after
following these procedures, proceed immediately with Steps 33-36. If the inflatable restraint
steering wheel module did deploy, proceed with Steps 28-32.
28. Put on a pair of shop gloves in order to protect your hands from possible heat and irritation
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when you handle the deployed inflatable restraint steering wheel module.
After the inflatable restraint steering wheel module has deployed, the surface of the air bag
may contain a powdery residue. This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates), and by-products of the chemical reaction. The deployment
reaction produces sodium hydroxide dust (similar to lye soap). The sodium hydroxide quickly
reacts with the atmospheric moisture. This atmospheric moisture converts the sodium
hydroxide into sodium carbonate and sodium bicarbonate (baking soda). Therefore, you will
probably find no sodium hydroxide present after the deployment. Gloves and safety glasses
are recommended. Gloves and safety glasses prevent possible irritation of the skin or eyes.
CAUTION: Immediately following the deployment of an air bag, the metal surfaces of the
inflator module are very hot. Do not place the deployed inflator module near any flammable
objects. Wait for about ten minutes before touching any metal surface of the inflator module.
Disregarding these precautions may cause fire or personal injury.
29. The metal canister and the area surrounding the inflatable restraint steering wheel module
are very hot. Do not touch the metal areas of the inflatable restraint steering wheel module
for about 10 minutes after deployment. Use care if you must move the deployed inflatable
restraint steering wheel module. Always wear gloves and handle the inflatable restraint
steering wheel module by the air bag or by the vinyl trim.
30. Disconnect the pigtail adapter from the inflatable restraint steering wheel module as soon
after the deployment as possible. This will prevent the hot inflatable restraint steering wheel
module canister from damaging either the pigtail adapter or the SIR deployment harness.
The pigtail adapter and the SIR deployment harness are reusable.
31. Inspect both the pigtail adapter and the SIR deployment harness for damage after each use.
Replace the pigtail adapter or the SIR deployment harness, as necessary.
32. Allow the deployed inflatable restraint steering wheel module to cool for at least 10 minutes.
Dispose of the deployed inflatable restraint steering wheel module through the normal refuse
channels.
33. Wash your hands with a mild soap and water.
Notice: Follow the remaining steps in the unlikely event that the inflatable restraint steering
wheel module did not deploy after following these procedures.
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34. Disconnect the SIR deployment harness from the power source. Confirm that you have
shorted the 2 banana plugs together.
35. Disconnect the pigtail adapter from the inflatable restraint steering wheel module.
36. Temporarily store the inflatable restraint steering wheel module with the vinyl trim cover
facing up.
37. Call the Technical Assistance group for further assistance.
Deployment Outside of the Vehicle (Inflatable Restraint

IP Module)
Caution: In order to prevent accidental deployment of the air bag which could cause personal
injury, do not dispose of an undeployed inflator module as normal shop waste. The undeployed
inflator module contains substances that could cause severe illness or personal injury if the sealed
container is damaged during disposal. Use the following deployment procedures to safely dispose of
an undeployed inflator module. Failure to dispose of an inflator module as instructed may be a
violation of federal, state, province, or local laws.
General Motors dealers should refer to the latest General Motors Service Bulletins for live
(undeployed) inflatable restraint IP module scrapping and disposal procedures. All others should
contact a local General Motors dealership for live inflatable restraint IP module scrapping and
disposal procedures. Dispose of deployed inflatable restraint IP modules through normal refuse
channels.
Deployment Inside Vehicle (Vehicle Scrapping Procedure)

Deploy the inflator modules inside of the vehicle when destroying the vehicle or when salvaging the
vehicle for parts. This includes but is not limited to the following situations:
The vehicle has completed its useful life.
Irreparable damage occurs to the vehicle in a non-deployment type accident.
Irreparable damage occurs to the vehicle during a theft.
The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as
opposed to rebuilding as the same VIN.
procedures in the order listed. Failure to follow the procedures in the order listed may result in
personal injury.
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1.
2.
3.
4.
5.
6.
Turn the ignition switch to the OFF position.

Remove the ignition key.
Put on safety glasses.
Remove all loose objects from the front seats.
Disconnect the inflatable restraint steering wheel module yellow 2-way connector.
Cut the yellow 2-way harness connector out of the vehicle, leaving at least 16 cm (6 in) of
wire at the connector.
7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
8. Cut 2 4.6 m (15 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand
wire. Use these wires in order to fabricate the driver deployment harness.
9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
10. Twist together 1 end from each of the wires in order to short the wires. Deployment wires
shall remain shorted, and not connected to a power source until you are ready to deploy the
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11. Twist together 1 connector wire lead to one deployment wire.

12. Verify that the previous connection is secure.
13. Bend flat the twisted connection.

14. Secure and insulate the connection using electrical tape.
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15. Twist together, bend, and tape the remaining connector wire lead to the remaining
deployment wire.
16. Connect the deployment harness to the inflatable restraint steering wheel module yellow 2way connector.
17. Route the deployment harness out of the vehicle's driver side.
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18. Disconnect the inflatable restraint IP module yellow 2-way harness connector.
19. Cut the harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the
connector.
20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads.
21. Cut 2 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand
wire. These wires will be used to fabricate the passenger deployment harness.
22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step.
23. Twist together 1 end from each of the wires in order to short the wires.
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24. Twist together 1 connector wire lead to 1 deployment wire.

25. Bend flat the twisted connection.

26. Secure and insulate the connection using electrical tape.
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27. Twist together, bend, and tape the remaining connector wire lead to the remaining
deployment wire.
28. Connect the deployment harness to the inflatable restraint IP module yellow 2-way
connector.
29.
30.
31.
32.
33.
Route the deployment harness out of the passenger side of the vehicle.
Clear the inside and outside of the vehicle of any people or loose and flammable objects.
Stretch the driver harness to full length.
Stretch the passenger harness to full length.
Completely cover the windshield and front door window openings with a drop cloth.
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34. Place a power source, 12 volt minimum/2 amp minimum (vehicle battery) near the shorted
end of the harness.
35. Separate the 2 ends of the driver deployment harness wires.
36. Connect the driver deployment harness wires to the power source in order to deploy the
inflatable restraint steering wheel module.
37. Disconnect the driver deployment harness wires from the power source.
38. Separate the 2 ends of the passenger deployment harness wires.

39. Connect the passenger deployment harness wires to the power source in order to deploy the
inflatable restraint IP module.
40. Disconnect the passenger deployment harness wires from the power source.
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41. Twist together 1 end of each wire on the driver deployment harness in order to short the
wires.
42. Twist together 1 end of each wire on the passenger deployment harness in order to short the
wires.
43. Remove the drop cloth from the vehicle.
44. Disconnect both harnesses from the vehicle.
45. Discard the harnesses.
46. Scrap the vehicle in the same manner as a non-SIR equipped vehicle.
46.1. Remove the undeployed module(s) from the vehicle. Refer to Inflatable Restraint
Steering Wheel Module Replacement and Inflatable Restraint Instrument Panel Module
Replacement .
46.2. Temporarily store the module(s).
46.3. Call the Technical Assistance Group for further assistance.
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Handling a Deployed Inflator Module

After the inflator module has deployed, the surface of the air bag may contain a powdery residue.
this powder consists primarily of cornstarch (used to lubricate the bag as it inflates), and byproducts of the chemical reaction. The deployment reaction produces sodium hydroxide dust
(similar to lye soap). The sodium hydroxide quickly reacts with the atmospheric moisture. This
atmospheric moisture converts the sodium hydroxide into sodium carbonate and sodium
bicarbonate (baking soda). Therefore, you will probably find no sodium hydroxide present after the
deployment. Gloves and safety glasses are recommended. Gloves and safety glasses prevent
possible irritation of the skin or eyes.
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Page 1 of 2

Automatic Transaxle - 4T60-E | Specifications | Document ID: 39864
1996 Buick Skylark
Fastener Tightening Specifications (Unit Repair)

Part
Number
Description of Use
Specifications
Qty Thread Size
Metric
English
Bolt, Case Extension
M10 x 1.5 x
35.0
35.5 Nm 26.0 lb ft
Bolt, Speed Sensor
M8 x 1.25 x
12.0
11.0 Nm 97.5 lb in
12
Bolt, FWD Servo Cover
M6 x 1.0 x
20.0
10.0 Nm 88.5 lb in
23
Bolt, Oil Pan
20
M6 x 1.0 x
17.0
11.5 Nm 95.0 lb in
28
Ball Check Assembly, Cooler
3/8-18
52.0 Nm 38.5 lb ft
29
Connector--Cooler (Inverted Flared

Tube)
1/4-18
38.0 Nm 28.0 lb ft
30
Bolt, Modulator
M8 x 1.25 x
20.0
23.5 Nm 17.3 lb ft
38
Plug, Pipe--(Line Pressure)
1/8-27
10.5 Nm 93.0 lb in
50
Nut, Case Side Cover (Flanged Hex)
M6 x 1.0
8.0 Nm 71.2 lb in
52
Screw and Conical Washer Assembly
17
M8 x 1.25 x
21.3
11.0 Nm 97.5 lb in
56
Bolt, Metric Hex (Structural Side

Cover)
11
M8 x 1.25 x
25.0
23.5 Nm 17.3 lb ft
57
Bolt, Torx Head (Structural Side

Cover)
M8 x 1.25 x
21.0
23.5 Nm 17.3 lb ft
58
Stud, Structural Side Cover to Case
M8 x 1.25 x
25.0
23.5 Nm 17.3 lb ft
103
Bolt, 2-1 Manual Servo Cover
M8 x 1.25 x
25.0
23.5 Nm 17.3 lb ft
131
Bolt, Hex Flange (Accumulator Cover

and Housing)
11
M6 x 1.0 x
28.0
11.0 Nm 97.5 lb in
204
Bolt, Pump Cover to Valve Body
M6 x 1.0 x
45.0
11.0 Nm 97.5 lb in
205
Bolt, Pump Cover to Pump Body
M8 x 1.25 x
20.0
23.5 Nm 17.3 lb ft
206
Bolt, Pump Body to Case
M8 x 1.25 x
95.0
23.5 Nm 17.3 lb ft
207
Bolt, Pump Cover to Channel Plate
M6 x 1.0 x
85.0
11.0 Nm 97.5 lb in
375
Bolt, Valve Body to Case
M8 x 1.25 x
70.0
23.5 Nm 17.3 lb ft
376
Bolt, Valve Body to Channel Plate
M6 x 1.0 x
35.0
11.0 Nm 97.5 lb in
10/14/2010
Document ID: 39864
Page 2 of 2
377

(Torx)
M6 x 1.0 x
45.0
12.0 Nm 9.0 lb ft
378
M6 x 1.0 x
55.0
11.0 Nm 97.5 lb in
379
Bolt, Special, Valve Body to Case
M8 x 1.25 x
85.0
23.5 Nm 17.3 lb ft
380
Bolt, Valve Body to Case
M8 x 1.25 x
90.0
23.5 Nm 17.3 lb ft
434
Bolt, Channel Plate to Case
M8 x 1.25 x
45.0
23.5 Nm 17.3 lb ft
436
Bolt, Channel Plate to Case
M8 x 1.25 x
30.0
23.5 Nm 17.3 lb ft
450
Temperature Sensor
1/8-27
7.0 Nm 62.0 lb in
524
Screw, Case to Drive Sprocket Support
M8 x 1.25 x
23.5
23.5 Nm 17.3 lb ft
803
Nut, Manual Shaft to Detent Lever
M10 x 1.5
31.5 Nm 23.2 lb ft
805
Bolt, Special, Manual Detent Sprig to

Channel Plate
M6 x 1.0 x
16.0
11.0 Nm 97.5 lb in
10/14/2010
Document ID: 39105
Page 1 of 1

1996 Buick Skylark
Range Reference
Range Reference Chart
Range
Park Reverse Neutral
Gear
OD
1st 2nd 3rd 4th 1st 2nd 3rd 1st 2nd
1st
1-2 Shift
Solenoid
ON
ON
ON
ON OFF OFF ON
@
ON
@
OFF
@
OFF
@
ON
@
OFF @ON
2-3 Shift
Solenoid
ON
ON
ON
@
ON ON OFF OFF ON
@
ON
@
OFF
@
ON
@
ON
4th Clutch
--
--
--
--
--
--
--
--
--
--
--
Reverse Band
--
--
--
--
--
--
--
--
--
--
--
2nd Clutch
--
--
--
--
--
--
--
3rd Clutch
--
--
--
--
--
--
--
--
--
3rd Sprag
Clutch
--
--
--
--
--
--
--
--
--
Input Clutch
--
--
Input Sprag
Clutch
--
--
2/1 Band
--
--
--
--
--
--
--
--
--
--
1/2 Support
Roller Clutch
--
--
--
Forward Band
--
--
--
l
l
l
l
l
l
l
@ON
A = Applied
H = Holding
O = Overrun
* Applied but not effective
@ The solenoid's state follows a shift pattern which depends upon vehicle speed,
throttle position, and selected gear range.
ON = The solenoid is energized.
OFF = The solenoid is de-energized
10/14/2010
Document ID: 48279
Page 1 of 1

1996 Buick Skylark
Shift Speed
Hydra-Matic 4T60-E Shift Speed Chart
Transmission Model
6BSW
6CUW
Engine Displacement
3.1L
2.4L
Engine RPO Code
L82
LD9
Engine VIN Code
Overall Axle Ratio
2.93
3.42
Final Drive Ratio
3.29
3.05
Drive/Driven Sprocket Teeth
37/33
33/37
Minimum Throttle 1-2 Upshift
Wide Open Throttle 1-2 Upshift
43
42
20
16
82
80
32
23
N/A
102
Minimum TCC Apply - Third Gear
45
33
Minimum TCC Apply - Fourth Gear
48
44
N/V Ratio - Third Gear/TCC On
46
48
N/V Ratio - Fourth Gear/TCC On
32
34
Vehicle Series
l
l
l
N/V Ratio = Engine RPM to Vehicle Speed Ratio

N/A = Not Available
Speeds are indicated in Miles Per Hour (MPH). MPH = Km/h x 1.609
10/14/2010
Document ID: 59569
Page 1 of 1

1996 Buick Skylark
Temperature Versus Resistance

Temperature vs Resistance
Temperature Temperature
Minimum
Resistance
Nominal
Resistance
Maximum
Resistance
Signal
ohms
ohms
ohms
volts
-40
-40
90636
100707
110778
5.00
-22
-30
47416
52684
57952
4.78
-4
-20
25809
28677
31545
4.34
14
-10
14558
16176
17794
3.89
32
8481
9423
10365
3.45
50
10
5104
5671
6238
3.01
68
20
3164
3515
3867
2.56
86
30
2013
2237
2461
1.80
104
40
1313
1459
1605
1.10
122
50
876
973
1070
3.25
140
60
600
667
734
2.88
158
70
420
467
514
2.56
176
80
299
332
365
2.24
194
90
217
241
265
1.70
212
100
159
177
195
1.42
230
110
119
132
145
1.15
248
120
89.9
99.9
109.9
0.87
266
130
69.1
76.8
84.5
0.60
284
140
53.8
59.8
65.8
0.32
302
150
42.5
47.2
51.9
0.00
10/14/2010
Document ID: 39865
Page 1 of 1

1996 Buick Skylark
End Play Specifications

Thrust Washer Selection Guide
ID Number
Dimension (mm)
Dimension (in)
Color
2.90-3.00
0.114-0.118
Orange/Green
3.05-3.15
0.120-0.124
Orange/Black
3.20-3.30
0.126-0.130
Orange
3.35-3.45
0.132-0.136
White
3.50-3.60
0.138-0.142
Blue
3.65-3.75
0.144-0.148
Pink
3.80-3.90
0.150-0.154
Brown
3.95-4.05
0.156-0.159
Green
4.10-4.20
0.161-0.165
Black
10
4.25-4.35
0.167-0.171
Purple
11
4.40-4.50
0.173-0.177
Purple/White
12
4.55-4.65
0.179-0.183
Purple/Blue
13
4.70-4.80
0.185-0.189
Purple/Pink
14
4.85-4.95
0.191-0.195
Purple/Brown
15
5.00-5.10
0.197-0.200
Purple/Green
10/14/2010
Document ID: 43486
Page 1 of 1

1996 Buick Skylark
Oil Pump Specifications

Oil Pump Specifications (4T60-E)
Thickness (mm)
Thickness (in)
17.953-17.963
0.7068-0.7072
17.963-17.973
0.7072-0.7076
17.973-17.983
0.7076-0.7080
17.983-17.993
0.7080-0.7084
17.993-18.003
0.7084-0.7088
18.003-18.013
0.7088-0.7092
17.943-17.961
0.7064-0.7071
17.961-17.979
0.7071-0.7078
17.979-17.997
0.7078-0.7085
Rotor Selection
Slide Selection
Vane Selection
10/14/2010
Document ID: 39867
Page 1 of 1

1996 Buick Skylark
Fluid Capacity Specifications

Liters
Quarts
Bottom Pan Removal
7.0
7.4
Complete Overhaul
9.5
10.0
Dry
12.7
13.4
(approximate)
10/14/2010
Document ID: 48298
Page 1 of 1

1996 Buick Skylark
Line Pressure
Hydra-matic 4T60-E Transmission
Range
Models
kPa
psi
Minimum Line Pressure: 1250 RPM 61 kPa

(18" Hg) Vacuum
D4, D3,
D2
BSW,
CUW
512-596
74-86
--
D1
BSW,
CUW
921-1333
134193
--
P, R, N
BSW,
CUW
460-696
67-101
Full Line Pressure: 1250 RPM 0 kPa (0" Hg)

Vacuum
D4, D3,
D2
BSW,
CUW
11481400
166203
--
D1
BSW,
CUW
921-1333
134193
--
P, R, N
BSW,
CUW
15401898
223275
10/14/2010
Document ID: 39877
Page 1 of 3

1996 Buick Skylark
Model Build Information

Table A
Transmission Model
6ACW
6AFW
6ASW
6HBW
6BSW
Vehicle Series
C,H
C,H
Engine Displacement
3.8l
3.1L
3.8L
3.8L
3.1L
Engine RPO Code
L36
L82
L36
L36
L82
Engine VIN Code
Overall Axle Ratio
3.06
3.33
2.84
3.06
2.93
Final Drive Ratio
3.06
3.33
2.84
3.06
3.29
35/35
35/35
35/35
35/35
37/33
30
30
30
30
30
Final Drive Assembly
STD
STD
STD
STD
FP
Output Shaft
STD
STD
STD
STD
STD
Torque Converter K-factor
163
180
122
163
140
Converter Clutch
TCC
TCC
TCC
TCC
TCC
STEEL
SSC
STEEL
SSC
SSC
SSC Mount Bolt Pattern
N/A
4 BOLT
N/A
4 BOLT
6 BOLT
Transmission Vent Assembly
CAP
CAP
CAP
CAP
TUBE
Temperature Sensor
391
391
391
391
391
1-2 Accumulator Valve (Primary)
STD
INVERT
STD
STD
STD
1-2 Accumulator Piston
136B
136C
136B
136B
136A
139A,D
139A,C
139A,D
139A,D
139A
136A
136A
136A
136A
136A
2-3 Accumulator Spring(s)
138A,B
138A,B
138A,B
138A,B
138A,B
423,4,5
423,4
423,4,5
423,4,5
423,4

VSS Rotor Teeth
Case Side Cover Pan

Notes:
l
l
l
l
l
l
l
l
FP = Fine Pitch
HD = Heavy Duty
N/A = Not Available
SSC = Case Aluminum Structural Side Cover Pan
STD = Standard
STEEL = Stamped Steel Side Cover Pan
VSS = Vehicle Speed Sensor
K-factor = Torque converter numeric rating (combines stall speed and torque
multiplication ratings)
This chart does not identify all unique build items and this chart may be subject to change.
Table B
Transmission Model
6BXW
6CAW
6CTW
6CUW
6PAW
10/14/2010
Document ID: 39877
Vehicle Series
Page 2 of 3
Engine Displacement
3.8L
3.8L
3.8L
2.4L
3.1L
Engine RPO Code
L36
L36
L67
LD9
L82
Engine VIN Code
Overall Axle Ratio
3.06
3.05
2.93
3.42
2.97
Final Drive Ratio
3.06
3.05
3.29
3.05
3.33
35/35
35/35
37/33
33/37
37/33
30
30
30
30
30
STD
FP
FP,HD
FP
STD
Output Shaft
STD
STD
LONG
STD
STD
163
163
163
203
140
Converter Clutch
TCC
TCC
TCC
TCC
TCC
STEEL
SSC
SSC
SSC
STEEL
N/A
6 BOLT
6 BOLT
6 BOLT
N/A
CAP
CAP
CAP
TUBE
CAP
Temperature Sensor
391
391
450
N/A
391
STD
STD
STD
STD
STD
136B
136B
136A
136A
136B
139A,D
139A,D
139A
139A
139A,D
136A
136A
136A
136A
136A
138A,B
138A,B
138A,B
138A,B
138A,B
423,4,5
423,4,5
423,4
423,4
423,4

VSS Rotor Teeth
Case Side Cover Pan

Notes:
l
l
l
l
l
l
l
l
FP = Fine Pitch
HD = Heavy Duty
N/A = Not Available
STD = Standard
Table C
Transmission Model
6PBW
6PKW
6WFW
6YLW
6YRW
C,H
Engine Displacement
3.4L
3.4L
3.1L
3.8L
3.8L
Engine RPO Code
LQ1
LA1
L82
L67
L67
Engine VIN Code
Overall Axle Ratio
3.43
3.29
2.93
2.93
2.93
Final Drive Ratio
3.06
3.29
3.29
3.29
3.29
Vehicle Series
10/14/2010
Document ID: 39877
Page 3 of 3
33/37
35/35
37/33
37/33
37/33
30
30
30
30
30
STD
FP
FP
FP,HD
FP,HD
Output Shaft
STD
STD
STD
LONG
LONG
177
163
140
163
163
ECCC
TCC
TCC
TCC
TCC
SSC
STEEL
SSC
STEEL
STEEL
4 BOLT
4 BOLT
6 BOLT
N/A
N/A
CAP
CAP
TUBE
CAP
CAP
Temperature Sensor
391
391
391
450
450
STD
STD
STD
STD
STD
136B
136A
136A
136A
136A
139A,D
139A
139A
139A
139A
136A
136A
136A
136A
136A
138A,B
138A,B
138A,B
138A,B
138A,B
423,4
423,4
423,4
423,4
423,4
VSS Rotor Teeth
Converter Clutch
Case Side Cover Pan

Notes:
l
l
l
l
l
l
l
l
FP = Fine Pitch
HD = Heavy Duty
N/A = Not Available
STD = Standard
10/14/2010
Document ID: 39107
Page 1 of 1

1996 Buick Skylark
Component Resistance (VIN M)

Component Resistance Chart
Cavities
Component
Resistance @ 20 Resistance @ 88
C (68F)
C (190F)
A-E
1-2 Shift Solenoid valve
19-24ohms
24-31ohms
B-E
19-24ohms
24-31ohms
C-E
Torque Converter Clutch (TCC) Pulse

Width Modulation (PWM) Solenoid valve
10-12ohms
13-15ohms
D-E
Torque Converter Clutch (TCC) Solenoid

valve
19-24ohms
24-31ohms
F-G
Automatic Transmission Fluid

Temperature (TFT) Sensor
varies with temperature
When components are at temperatures other than 20C (68F)
10/14/2010
Document ID: 48280
Page 1 of 1

1996 Buick Skylark
Component Resistance (VIN T)

Note: This diagnostic procedure is written for all components at 20C (68F).
The accompanying component resistance chart may be helpful when components are at
temperatures other than 20C (68F).
Component Resistance Chart

Component
Cavities
Resistance @ 20 Resistance @ 88
C (68F)
C (190F)
A-E
19-24ohms
24-31ohms
B-E
19-24ohms
24-31ohms
C-E
Torque Converter Clutch (TCC) Pulse

Width Modulation (PWM) Solenoid valve
10-12ohms
13-15ohms
D-E
Torque Converter Clutch (TCC) Solenoid

valve
19-24ohms
24-31ohms
10/14/2010
Document ID: 209175
Page 1 of 2

Automatic Transaxle - 4T60-E | Component Locator | Document ID: 209175
1996 Buick Skylark
Transmission Major Component Locations
(1) Torque Converter Assembly

(2) Manual Shaft
(3) Reverse Servo Assembly
(4) Parking Lock Actuator
(5) 3rd Sprag Clutch Assembly
(6) Input Sprag Clutch Assembly
(7) Input Carrier Assembly
(8) Reaction Carrier Assembly
(9) 1-2 Support Assembly
(10) 1-2 Support Roller Clutch Assembly
(11) Final Drive Differential Assembly
10/14/2010
Document ID: 209175
Page 2 of 2
(12) Speed Sensor

(13) Case Extension
(14) Forward Servo Assembly
(15) Forward Band Assembly
(16) 2-1 Band Assembly
(17) 2-1 Manual Servo Assembly
(18) Input Clutch Assembly
(19) 3rd Clutch Assembly
(20) 2nd Clutch Assembly
(21) Reverse Band Assembly
(22) Driven Sprocket Support
(23) Filter Assembly
(24) Driven Sprocket
(25) 4th Clutch Assembly
(26) 4th Clutch Hub and Shaft Assembly
(27) Output Shaft
(28) Drive Link Assembly
(29) 3-4 Accumulator Assembly
(30) Channel Plate Assembly
(31) Drive Sprocket
(32) Control Valve Body Assembly
(33) Pump Assembly
10/14/2010
Document ID: 44166
Page 1 of 2

1996 Buick Skylark
Case and Associated Parts (1 of 4)
(50) Case Side Cover Nut M6 1.0 (6)

(51) Conical Washer (6)
(52) Screw and Conical Washer Assembly--Side Cover M8 X 1.25 X 21.3 (17)
(53) Case Side Cover Pan
(54) Case Side Cover Gasket
(55) Inner Case Side Cover Gasket
(56) Structural Side Cover Metric Hex Bolt (11)
(57) Structural Side Cover Torx Head Bolt (4)
(58) Structural Side Cover to Case Stud (2)
(59) Structural Side Cover to Channel Plate Seal
(200) Oil Pump Complete Body Assembly
(204) Pump Cover to Valve Body Bolt M6 X 1.0 X 45.0 (1)
(205) Pump Cover to Pump Body Bolt M8 X 1.25 X 20.0 (1)
(206) Pump Body to Case Bolt M8 X 1.25 X 95.0 (2)
(207) Pump Cover to Channel Plate Bolt M6 X 1.0 X 85.0 (10)
(207) Pump Cover to Channel Plate Bolt M6 X 1.0 X 85.0 (10)
(224) Wiring Harness Assembly
(225) Conduit Clip
10/14/2010
Document ID: 44166
Page 2 of 2
(226) Conduit Clip

(300) Control Valve Body Assembly
(369) Channel Plate/Spacer Plate Gasket
(370) Valve Body Spacer Plate Assembly
(371) Valve Body to Spacer Plate Assembly
(372) 0.25 Diameter Ball
(373) Ball
(374) Filter
(374) Filter
(375) Valve Body to Case Bolt M8 X 1.25 X 70.0 (3)
(377) Valve Body to Channel Plate Bolt M6 X 1.0 X 45.0 (2)
(378) Valve Body to Channel Plate Bolt M6 X 1.0 X 55.0 (6)
(379) Special Valve Body to Case Bolt M8 X 1.25 X 85.0 (1)
(382) Converter Clutch Assembly Screen Assembly
(383) Seal, TCC Screen (O-Ring)
(390) Temperature Sensor Clip
(391) Temperature Sensor
10/14/2010
Document ID: 44163
Page 1 of 3

1996 Buick Skylark
(1) Complete Converter Assembly

(2) Converter Pump Bushing
(3) Transmission Case
(4) Axle Oil Seal Assembly
(5) Case Extension Bolt M10 X 1.5 X 35.0
(6) Case Extension
(7) Differential to Case Bushing
(7b) Differential to Case Bearing (Heavy Duty)
(8) Extension to Case seal
(9) Speed Sensor Bolt M8 X 1.25 X 12.0
(9) Speed Sensor Bolt M8 X 1.25 X 12.0
10/14/2010
Document ID: 44163
Page 2 of 3
(10) Complete Speed Sensor Assembly

(11) O-Ring Speed Sensor Seal
(12) FWD Servo Cover Bolt M6 X 1.0 X 20.0
(13) Forward servo Cover
(14) O-Ring Seal (Servo Cover)
(15) Internal Retaining Ring
(16) Servo Forward Piston
(17) Servo Spring Retainer (1st and 2nd)
(17) Servo Spring Retainer (1st and 2nd)
(18) Oil Seal Piston
(19) Forward Servo Cushion Spring
(20) Servo Cushion Spring Retainer
(21) Forward Band Apply Pin
(22) Servo Return Spring
(23) Special Transmission Oil Pan M8 X 1.25 X 18.0
(24) Transmission Oil Pan
(25) Transmission Oil Pan Gasket
(26) Chip Collector Magnet
(27) Oil Reservoir Weir
(28) Check Assembly Cooler Ball 3/8-18
(29) Cooler line Connector (Inverter Flared Tube 1/4-18
(30) Modulator Bolt M8 X 1.25 X 20.0
(30) Modulator Bolt M8 X 1.25 X 20.0
(31) Modulator retainer
(32) Transmission Modulator Assembly
(33) O-Ring Seal
(34) Modulator Valve
(35) Electrical Connector (7 Way)
(36) O-Ring Seal
(37) Transmission Vent Assembly
(37) Transmission Vent Assembly
(38) Pipe Plug 1/8 27
(39) Servo Cover Retaining Ring
(40) Servo Cover
(41) O-Ring Seal (Servo Cover)
(42) Internal Retaining Ring
(43) Oil Seal Piston Ring
(44) Servo reverse Piston
(45) Reverse Servo Cushion Spring
(46) Servo Cushion Spring Retainer
(48) Reverse Apply Pin
(49) Servo Return Spring
(100) Transmission Oil Filter Assembly
(101) Filter Neck To case seal Assembly
(227) Oil Pump Drive Shaft Assembly
10/14/2010
Document ID: 44163
Page 3 of 3
(228) Oil seal Pump Shaft Ring

(372) Ball 0.25 Dia.
(372) Ball 0.25 Dia.
(400) Complete Channel Plate Assembly
10/14/2010
Document ID: 44151
Page 1 of 2

1996 Buick Skylark
(3)
Transmission Case
(102) Band Anchor Pin

(400) Complete Channel Plate Assembly
(431) Channel Plate 4th Clutch Hub and Bearing Assembly
(434) Channel Plate to Case Bolt M8 X 1.25 mm X 45.0 mm
(436) Channel Plate to Case Bolt M8 X 1.25 mm X 30.0 mm
(500) 4th Clutch Backing Plate
(501) 4th Clutch Plate Assembly
(501) 4th Clutch Plate Assembly
(502) 4th Clutch Apply Plate
(502) 4th Clutch Apply Plate
(504) 4th Clutch Hub and Shaft Assembly
(505) Thrust Washer (4th Clutch Hub to Driven Sprocket)
(506) Driven Sprocket
(507) Drive Link Assembly
(508) Thrust Washer (Driven and 2nd Clutch Drum)
(509) Output Shaft/Drive Axle Ring
(510a) Output Shaft (Standard)
10/14/2010
Document ID: 44151
Page 2 of 2
(510b) Output Shaft (Heavy Duty)

(511) 4th Clutch/Output Shaft Bearing
(512) Inboard Output Shaft Differential Ring
(513) Oil Seal Ring (Turbine Shaft/Sleeve)
(514) Thrust Washer (Drive Sprocket/Channel Plate)
(515) Turbine Shaft to Drive Sprocket Ring (Snap)
(516) Drive Sprocket
(517) Thrust Washer (Drive Sprocket/Support)
(518) Turbine Shaft
(519) Oil Seal Ring
(520) O-Ring Seal
(521) Drive Support/Sprocket Bearing Assembly
(522) Drive Sprocket Support
(523) Drive Sprocket Support Bushing
(524) Drive Sprocket Support Screw M8 X 1.25 mm X 23.5 mm
(525) Converter Oil Helix Seal Assembly
(526) Pin, Dowel
(526) Pin, Dowel
(808) Guide Retaining Pin
(809) Actuator Guide
(810) O-Ring Seal
10/14/2010
Document ID: 44149
Page 1 of 2

1996 Buick Skylark
(3)
Transmission Case
(103) 2-1 Manual Servo Cover Bolt M8 X 1.25mm X 25.0mm (3)

(104) 2-1 Manual Servo Body Cover
(105) 2-1 Servo Square Cut Seal
(106) Bottom Retaining Clip
(107) Lip Seal
(108) 2-1 Manual Servo Piston
(109) 2-1 Manual Servo Cushion Spring
(110) Internal Servo Spring Manual Cushion Retainer
(111) 2-1 Manual Apply Pin
(112) 2-1 Manual Servo Return Spring
(113) O-Ring Seal
(114) 2-1 Manual Servo Body
(115) 2-1 Servo Filter
(117) Band Anchor Forward and Reverse Pin
(117) Band Anchor Forward and Reverse Pin
(120) Thermo Element Pin Washer Assembly
(121) Thermostatic Element
10/14/2010
Document ID: 44149
Page 2 of 2
(122) Thermostatic Element Plate

(123) Thermal Element Pin
(124) Forward Servo Apply Pipe
(125) Manual Servo Apply Pipe
(126) Lube Oil Pipe
(127) Hose Clamp
(127) Hose Clamp
(128) Lube Oil Hose
(129) Lube Pipe Clip Retainer
(130) Pipe and Washer Assembly
(131) Accumulator Cover and Housing Hex Flange Bolt M6 X 1.0mm X 28.0mm (11)
(132) Accumulator Cover
(133) Accumulator Cover Gasket
(133) Accumulator Cover Gasket
(134) Accumulator Spacer Plate
(135) Pin, 2-3 Accumulator
(136a) Conventional 1-2 and 2-3 Accumulator Piston
(136b) Offset 1-2 and 2-3 Accumulator Piston
(136c) Inverted 1-2 and 2-3 Accumulator Piston
(137) Oil Seal Accumulator Piston Ring
(138a) Inner 2-3 Accumulator Spring
(138b) Outer 2-3 Accumulator Spring
(139a) Outer 1-2 Accumulator Spring
(139b) Inner 1-2 Accumulator Spring
(139b) Inner 1-2 Accumulator Spring
(139c) Outer 1-2 Accumulator Spring
(139d) 1-2 Accumulator Assist Spring and Retainer Assembly
(140) Machined Accumulator Housing
10/14/2010
Document ID: 44148
Page 1 of 2

1996 Buick Skylark
Oil Pump Assembly
(201) Pump Cover

(202) Oil Pump Body
(205) Pump Cover to Pump Body Bolt - M8 X 1.25mm X 20.0mm (1)
(208) Auxiliary Valve Body Bushing (Pump Shaft)
(209) Pump Vane Ring
10/14/2010
Document ID: 44148
Page 2 of 2
(209) Pump Vane Ring

(210) Oil Pump Selective Rotor
(211) Pump Selective Vane
(212) Slide to Cover Selective Oil Seal Ring
(213) O-Ring Seal
(214) Oil Pump Selective Slide
(215) Pump Slide Pivot Pin
(219) Oil Pump Pressure Screen Assembly
(220) Pump Slide Seal
(221) Oil Pump Slide Seal Support
(222) Outer Pump Priming Spring
(223) Inner Pump Priming Spring
10/14/2010
Document ID: 44171
Page 1 of 2

1996 Buick Skylark
Control Valve Body Assembly (1 of 2)
(301) Control Valve Body (Machined)

(314) Spring Clip Retainer
(315) Solenoid Assembly
(316) O-Ring Seal
(338) 1-2 Accumulator Plug Retainer (Primary and Secondary)
(338) 1-2 Accumulator Plug Retainer (Primary and Secondary)
(339) 1-2 Accumulator Plug (Primary)
(339) 1-2 Accumulator Plug (Primary)
(340) 1-2 Accumulator Valve Spring (Primary)
(340) 1-2 Accumulator Valve Spring (Primary)
(341) 1-2 Accumulator Valve
(342) 1-2 Accumulator Valve Bushing (Primary)
(342) 1-2 Accumulator Valve Bushing (Primary)
(344) 2-3 Accumulator Valve Spring
(345) 2-3 Accumulator Valve Bushing
10/14/2010
Document ID: 44171
Page 2 of 2
(346) 1-2 Accumulator Plug (Secondary)

(347) 1-2 Accumulator Valve (Secondary)
(348) 1-2 Accumulator Valve Spring (Secondary)
(349) 1-2 Accumulator Bushing (Secondary)
(351) 3-4 Accumulator Valve Spring
(353) 2-3 Shift Retainer
(354) 2-3 Shift Bore Plug
(355) 3-2 Downshift Valve Spring
(356) 3-2 Manual Downshift Spring
(357) 2-3 Shift Valve
(359) 3-4 Shift Bore Plug
(360) 4-3 Manual Downshift Valve
(361) 4-3 Manual Downshift Spring
(363) Coiled Spring Pin
(364) Reverse Boost Bore Plug
(365) Servo Boost Valve Spring (Reverse)
(366) Servo Boost Valve Spring (Forward)
(367) Forward and Reverse Servo Boost Valve
(368) Oil Pump Drive Bearing and Sleeve
(385) Accumulator Bushing Assembly Retainer (2-3 and 1-2 Secondary and Primary)
(385) Accumulator Bushing Assembly Retainer (2-3 and 1-2 Secondary and Primary)
10/14/2010
Document ID: 44173
Page 1 of 2

1996 Buick Skylark
Control Valve Body Assembly (2 of 2)
(301) Machined Control Valve Body

(302) Line Boost Valve and Bushing Retainer
(303) Line Boost Valve Retainer
(304) Line Boost Valve
(305) Pressure Regulator Modulator Boost Spring
(306) Pressure Regulator Retainer
(307) Reverse Boost Spring
(308) Grooved Pin
(309) Reverse Boost Valve Bushing
(310) Reverse Boost Valve
(311) Outer Pressure Regulator Valve Spring
(312) Pressure Regulator Valve Isolator Spring
(313) Pressure Regulator Valve
(316) O-Ring Seal
10/14/2010
Document ID: 44173
Page 2 of 2
(316) O-Ring Seal

(320) Pump Pressure Relief Bushing
(322) Spring Seat
(324) 3-4 Shift Solenoid Retainer
(325) PWM Solenoid Assembly
(326) PWM Solenoid O-Ring
(327) PWM Solenoid O-Ring
(331) Isolator Spring
(332) Converter Clutch Regulator Valve
(333) Converter Clutch Regulator Spring
(334) Isolator Valve
(335) Converter Clutch Valve
(336) Converter Clutch Spring
(383) Converter Clutch Regulator Retainer
(384) Converter Clutch Regulator Bushing
10/14/2010
Document ID: 44158
Page 1 of 2

1996 Buick Skylark
Channel Plate Assembly
(401) Channel Plate

(402) Manual Valve Link
(403) Manual Valve Retainer Link
(404) Manual Valve
(405) Low Blow Off Plug
(406) Low Blow Off Spring
(409) Left Side Axle Oil Seal Assembly
(410) Control Valve Body Alignment Sleeve
(411) Bore Plug
(411) Bore Plug
(411) Bore Plug
10/14/2010
Document ID: 44158
Page 2 of 2
(412) Orificed Cup Plug

(417) Blow Off Cup Plug
(418) TCC Blow Off Spring
(420) 0.375" Diameter Ball
(421) 3-4 Accumulator Canister
(422) O-Ring Seal
(423) Outer 3-4 Accumulator Spring
(424) Middle 3-4 Accumulator Spring
(425) Inner 3-4 Accumulator Spring
(426) 3-4 Accumulator Pin
(427) 3-4 Accumulator Piston Oil Seal Ring
(428) 3-4 Accumulator Piston
(429) Lower Channel Plate Gasket
(430) Upper Channel Plate Gasket
(431) 4th Channel Hub to Channel Plate Bearing Assembly
(432) Channel Plate to Side Cover Stud M6 X 1.0mm X 18.0mm (6)
(514) Drive Sprocket/Channel Plate Thrust Washer
(526) Dowel Pin
(526) Dowel Pin
10/14/2010
Document ID: 44156
Page 1 of 3

1996 Buick Skylark
Internal Components (1 of 2)
(601) 4th Clutch Return Spring Snap Ring

(602) 4th Clutch Piston Return Spring Assembly
(603) 4th Clutch Piston
(604) 4th Clutch Piston Seal (Outer)
(605) 4th Clutch Piston Seal (Inner)
(606) Drawn Cup Bearing Assembly
(607) Orificed Cup Plug
(608) Chain Scavenging Scoop
(609) Driven Sprocket Support
(610) Cup Plug
(611) Thrust Washer (Driven Sprocket Support/2nd Clutch Drum)
10/14/2010
Document ID: 44156
Page 2 of 3
(612) Four Lobed Ring Seal

(613) Oil Seal Ring
(614) Driven Sprocket Support Bushing
(615) Reverse Band Assembly
(616) 75.5 O.D. X 8.0 Bushing
(617) 2nd Clutch Housing
(618) Check Valve Retainer and Ball Assembly (Forward Clutch)
(619) 70.0 O.D. X 11.0 Bushing
(620) 2nd Clutch Piston with Molded Seal
(621) 2nd Clutch Apply Ring and Release Spring Assembly
(622) Snap Ring
(623) 2nd Clutch Plate (Waved)
(624) 2nd Clutch Plate Assembly (Fiber)
(625) 2nd Clutch Reaction Plate (Steel)
(626) Backing Support Ring Plate (Steel)
(627) 2nd Clutch Snap Ring (Outer)
(628) Oil Seal Ring (Input Shaft)
(629) Thrust Bearing (Support Sprocket/Thrust Washer)
(630) Selective Thrust Washer (Bearing/Input Clutch Hub)
(631) Input Shaft Bushing
(632) Input Housing Sleeve and Shaft Assembly
(633) Check Valve Retainer and Ball Assembly
(634) Input Clutch Piston Seal (Inner)
(635) Input Clutch Piston Seal (Outer)
(636) Input Clutch Piston
(637) Input Spring and Retainer Assembly
(638) O-Ring Seal
(639) 3rd Clutch Piston Housing
(640) Snap Ring (3rd Clutch Piston Housing/Input Shaft
(640) Snap Ring (3rd Clutch Piston Housing/Input Shaft)
(641) 3rd Clutch Piston Seal (Inner)
(642) 3rd Clutch Piston Seal and Ball Capsule Assembly
(643) 3rd Clutch Spring Retainer and Guide Assembly
(644) Thrust Bearing Assembly
(645) 3rd Clutch Plate (Waved)
(646) 3rd Clutch Plate Assembly (Sprocket Support/Spline OD)
(647) 3rd Clutch Plate Assembly (Sprocket Support/Spline ID)
(648) Backing Plate
(649) Snap Ring
(654) Input Clutch Apply Plate
(655) Input Clutch Plate (Waved)
(656) Input Clutch Plate Assembly (Fiber)
(657) Input Clutch Plate (1.9 Flat)
(658) Clutch Backing Plate (Steel)
(659) Snap Ring
10/14/2010
Document ID: 44156
Page 3 of 3
(716) 2nd Clutch Apply Reaction Plate (Tapered)

(723) 4th Clutch Shaft to Input Housing Bearing
10/14/2010
Document ID: 44154
Page 1 of 3

1996 Buick Skylark
Internal Components (2 of 2)
(653) 3rd Sprag Clutch Outer Race

(661) Input Sprag Clutch Inner Race
(665) Input Sprag Clutch Outer Race
(667) Input Sun Gear Spacer
(668) Input Sun Gear
(669) Reverse Reaction Drum
(672) Complete Input Carrier Assembly
(673) Input Carrier to Reaction Carrier Dam
(674) Input/Reaction Carrier Thrust Bearing Assembly
(675) Reaction Complete Carrier Assembly
10/14/2010
Document ID: 44154
Page 2 of 3
(676) Reaction Carrier/Sun Gear Thrust Bearing Assembly

(677) Left Hand Reaction Sun Gear Bushing
(678) Reaction Sun Drum Bushing Assembly Gear
(679) Right Hand Reaction Sun Gear Bushing
(680) 2-1 Band Assembly
(683) 1-2 Support Roller Assembly
(685) Thrust Assembly/Low Race Bearing Assembly
(686) 1-2 Support Bushing
(687) 1-2 Support Inner Race
(688) Forward Band Assembly
(689) Final Drive Sun Gear Shaft
(690) Final Drive Internal Gear Bushing
(691) Thrust Washer (1/2 Support/Internal Gear)
(692) Snap Ring (Final Drive Internal Gear Sprocket)
(693) Final Drive Internal Gear
(694) Pawl Lockout Pawl and Pin Assembly
(695) Thrust Bearing Assembly (Internal Gear/Parking Gear)
(696) Parking Gear
(697) Final Drive Sun Gear
(698) Thrust Carrier/Sun Gear Bearing Assembly
(699) Spiral Pin Retaining Ring
(700) Complete Differential/Final Drive Carrier Assembly
(701) Differential Pinion Shaft
(702) Differential Pinion Shaft Retaining Pin
(703) Thrust Washer (Differential Pinion)
(703) Thrust Washer (Differential Pinion)
(704) Differential Pinon Gear
(704) Differential Pinon Gear
(705) Differential Side Gear
(705) Differential Side Gear
(706) Bronze Thrust Washer (Differential Side Gear)
(706) Bronze Thrust Washer (Differential Side Gear)
(708) Pinion Thrust Washer (Steel)
(708) Pinion Thrust Washer (Steel)
(709) Roller Needle Bearing
(710) Pinion Needle Bearing Spacer
(711) Final Drive Planet Pinion
(712) Planet Pinion Pin
(713) Speed Sensor Rotor (29 or 30 Teeth)
(714) Differential Carrier/Case Washer (Thrust)
(717) Spiral Lock Ring
(718) 3rd Clutch Sprag Retainer
(719) End Bearing
(719) End Bearing
10/14/2010
Document ID: 44154
Page 3 of 3
(720) 3rd Sprag Assembly

(721) Center Bearing
(722) Input Sprag Input
10/14/2010
Document ID: 44147
Page 1 of 1

1996 Buick Skylark
Manual Shaft and Park System Components
(800) Parking Lock Actuator Assembly

(801) Manual Shift to Case Pin
(802) Inside Detent Lever
(803) Manual Shaft/Detent Lever Nut (Hex) M10 X 1.5
(804) Manual Detent Spring and Roller Assembly
(805) Special Manual Detent Spring to Channel Plate Bolt M6 X 1.0 X 16.0
(806) Manual Shaft Seal
(807) Manual Shaft
(808) Guide Retaining Pin
(809) Actuator Guide
(810) O-Ring Seal
10/14/2010
Document ID: 44146
Page 1 of 2

1996 Buick Skylark
Thrust Washer and Bearing Locations
(7b) Differential to Case Bearing (Heavy Duty)

(368) Oil Pump Drive Bearing and Sleeve
(431) 4th Clutch Hub/Channel Plate Bearing Assembly
(505) Thrust Washer (4th Clutch Hub/Driven Sprocket)
(508) Thrust Washer (Driven and 2nd Clutch Drum)
(514) Thrust Washer (Drive Sprocket/Channel Plate)
(521) Drive Support/Sprocket Bearing Assembly (Drawn Cup)
(608) Drawn Cup Bearing Assembly
(611) Thrust Washer (Driven Sprocket Support/2nd Clutch Drum)
10/14/2010
Document ID: 44146
Page 2 of 2
(629) Thrust Bearing (Support Sprocket/Thrust Washer)

(630) Thrust Washer (Bearing/Input Clutch Hub) Selective
(674) Thrust Bearing Assembly (Input/Reaction Carrier)
(676) Thrust Bearing Assembly (Reaction Carrier/Sun Gear)
(685) Thrust Assembly/Low Race Bearing Assembly
(691) Thrust Washer (1-2 Support/Internal Gear)
(695) Thrust Bearing Assembly (Internal Gear/Parking Gear)
(698) Thrust Carrier/Sun Gear Bearing Assembly
(714) Differential Carrier/Case Washer (Thrust)
(715) Thrust Bearing Assembly (Differential Carrier/Case)
(723) 4th Clutch Shaft to Input Housing Bearing
10/14/2010
Document ID: 44145
Page 1 of 2

1996 Buick Skylark
Seal Locations
(4) Axle Oil Seal Assembly

(8) Extension to Case Seal
(11) O-Ring Speed Sensor Seal
(14) O-Ring Seal (Forward Servo Cover)
(18) Oil Seal Ring (Forward Servo Piston)
(41) O-Ring Seal (Reverse Servo Cover)
(43) Oil Seal Ring (Reverse Servo Piston)
(105) Square Cut Seal (2-1 Servo)
(107) Lip Seal (Manual 2-1 Servo Piston)
(113) O-Ring Seal (Manual 2-1 Servo Cover)
10/14/2010
Document ID: 44145
Page 2 of 2

(409) Axle Oil Seal Assembly (Left Side)
(422) O-Ring Seal
(427) Oil Seal Ring (3-4 Accumulator Piston)
(525) Converter Oil Helix Seal Assembly
(604) Fourth Clutch Piston Seal (Outer)
(605) Fourth Clutch Piston Seal (Inner)
(620) Second Clutch Piston with Molded Seal
(620) Second Clutch Piston with Molded Seal
(634) Input Clutch Piston Seal (Inner)
(635) Input Clutch Piston Seal (Outer)
(641) Third Clutch Piston Seal (Inner)
(642) Seal and Ball Capsule ASM., Third Clutch Piston
(642) Seal and Ball Capsule ASM., Third Clutch Piston
10/14/2010
Document ID: 44181
Page 1 of 1

1996 Buick Skylark
Electronic Component Locations
(10) Vehicle Speed Sensor

(315) 1-2 Shift Solenoid, 2-3 Shift Solenoid or TCC Solenoid
(325) PWM Solenoid
10/14/2010
Document ID: 44198
Page 1 of 1

1996 Buick Skylark
Pump Cover Fluid Passages (Oil Pump Body Side)
(2) Line
(17) Decrease
10/14/2010
Document ID: 44204
Page 1 of 1

1996 Buick Skylark
Oil Pump Body Fluid Passages (Pump Cover Side)
(1) Suction
(2) Line
(2) Line
(17) Decrease
(49) Exhaust
10/14/2010
Document ID: 44201
Page 1 of 1

1996 Buick Skylark
Oil Pump Body Fluid Passages (Control Valve Body Side)
(1) Suction
(2) Line
(2) Line
(2) Line
(17) Decrease
(49) Exhaust
10/14/2010
Document ID: 44219
Page 1 of 2

1996 Buick Skylark
Control Valve Body Fluid Passages (Oil Pump Side)
(1) Suction
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
(11) Converter Feed
(12) Regulated Apply
10/14/2010
Document ID: 44219
Page 2 of 2
(17) Decrease
(18) D-4
(18) D-4
(19) Drive Servo Apply
(26) 2nd
(30) 3rd
(38) 4th
(45) Low
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(50) Void
(50) Void
(50) Void
10/14/2010
Document ID: 44214
Page 1 of 4

1996 Buick Skylark
Control Valve Body Fluid Passages (Channel Plate Side)
(#5) Reverse--Reverse Servo Checkball (372)

(#6) D-4--Drive Servo Apply Checkball (373)
(#7) Low--Low-1st Checkball (372)
(#8) D-2--Manual 2-1 Servo Feed Checkball (372)
(#9) 3rd--3rd Clutch Checkball (372)
(#10) 4th--4th Clutch Checkball (372)
(1)
Suction
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
10/14/2010
Document ID: 44214
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
(2)
PRN
(3)
PRN
(4)
Solenoid B
(4)
Solenoid B
(5)
Solenoid A
(5)
Solenoid A
(6)
Input Clutch Feed
(7)
Input Clutch
(8)
PWM Feed
(8)
PWM Feed
(9)
PWM
(9)
PWM
Page 2 of 4
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(13) Release
(13) Release
(13) Release
(14) Apply
(14) Apply
(15) Cooler
(15) Cooler
(15) Cooler
10/14/2010
Document ID: 44214
Page 3 of 4
(17) Decrease
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(21) Auxiliary Input Clutch Feed
(22) Primary Trim
(22) Primary Trim
(22) Primary Trim
(23) 1-2 Accumulator
(26) 2nd
(26) 2nd
(27) 2nd/2nd Exhaust
(28) 2nd Clutch
(28) 2nd Clutch
(29) Solenoid B Off
(29) Solenoid B Off
(29) Solenoid B Off
(29) Solenoid B Off
(30) 3rd
(30) 3rd
(30) 3rd
(31) 3rd/3rd Exhaust
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(34) TCC Signal
(34) TCC Signal
(34) TCC Signal
(42) D-3
(42) D-3
10/14/2010
Document ID: 44214
Page 4 of 4
(43) D-2
(43) D-2
(43) D-2
(44) Manual 2-1 Servo Feed
(45) Low
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(47) Reverse
(47) Reverse
(48) Reverse Servo
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
(50) Void
(50) Void
(50) Void
(50) Void
(50) Void
(50) Void
10/14/2010
Document ID: 44186
Page 1 of 5

1996 Buick Skylark
Typical Spacer Plate Fluid Passages
(374) 1-2 Solenoid and 2-3 Solenoid Filter

(374) 1-2 Solenoid and 2-3 Solenoid Filter
(382) Converter Clutch Assembly Screen Assembly
(1) Suction
(1) Suction
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
(2) Line
10/14/2010
Document ID: 44186
Page 2 of 5
(2) Line
(2) Line
(2) Line
(2) Line
(3) PRN
(3) PRN
(4) Solenoid B
(4) Solenoid B
(4) Solenoid B
(5) Solenoid A
(5) Solenoid A
(5) Solenoid A
(6) Input Clutch Feed
(7) Input Clutch
(7) Input Clutch
(8) PWM Feed
(8) PWM Feed
(8) PWM Feed
(8) PWM Feed
(8) PWM Feed
(9) PWM
(9) PWM
(9) PWM
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(13) Release
10/14/2010
Document ID: 44186
Page 3 of 5
(13) Release
(13) Release
(13) Release
(14) Apply
(14) Apply
(14) Apply
(15) Cooler
(15) Cooler
(16) Lube
(16) Lube
(17) Decrease
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(20) Servo Apply
(20) Servo Apply
(20) Servo Apply
(20) Servo Apply
(21) Auxiliary Input Clutch Feed
(22) Primary Trim
(22) Primary Trim
(22) Primary Trim
(22) Primary Trim
(22) Primary Trim
10/14/2010
Document ID: 44186
Page 4 of 5

(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(26) 2nd
(28) 2nd Clutch
(28) 2nd Clutch
(28) 2nd Clutch
(28) 2nd Clutch
(29) Solenoid B Off
(29) Solenoid B Off
(29) Solenoid B Off
(30) 3rd
(30) 3rd
(30) 3rd
(30) 3rd
(30) 3rd
(30) 3rd
(30) 3rd
(31) 3rd/3rd Exhaust
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(33) 3rd Clutch/Low-1st
(34) TCC Signal
(34) TCC Signal
(34) TCC Signal
(34) TCC Signal
(34) TCC Signal
(38) 4th
10/14/2010
Document ID: 44186
Page 5 of 5
(38) 4th
(38) 4th
(38) 4th
(40) 4th Clutch
(40) 4th Clutch
(42) D-3
(42) D-3
(43) D-2
(43) D-2
(43) D-2
(45) Low
(45) Low
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(47) Reverse
(47) Reverse
(47) Reverse
(48) Reverse Servo
(48) Reverse Servo
(48) Reverse Servo
(49) Exhaust
(49) Exhaust
(49) Exhaust
10/14/2010
Document ID: 44213
Page 1 of 4

1996 Buick Skylark
Channel Plate Fluid Passages (Control Valve Body Side)
(#1) Release--TCC Apply Checkball (372)

(#2) 2nd--2nd Clutch Checkball (372)
(#3) PRN--Input Clutch Checkball (372)
(#4) 3rd Clutch--Low-1st Checkball (372)
(1) Suction
(2) Line
(2) Line
(2) Line
(2) Line
(3) PRN
(3) PRN
10/14/2010
Document ID: 44213
Page 2 of 4
(3) PRN
(4) Solenoid B
(5) Solenoid A
(7) Input Clutch
(8) PWM Feed
(9) PWM
(9) PWM
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(10) Modulator
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(11) Converter Feed
(13) Release
(13) Release
(13) Release
(14) Apply
(14) Apply
(15) Cooler
(15) Cooler
(16) Lube
(16) Lube
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(18) D-4
(22) Primary Trim
(22) Primary Trim
10/14/2010
Document ID: 44213
Page 3 of 4

(26) 2nd
(27) 2nd-2nd Exhaust
(28) 2nd Clutch
(28) 2nd Clutch
(28) 2nd Clutch
(28) 2nd Clutch
(29) Solenoid B Off
(29) Solenoid B Off
(30) 3rd
(30) 3rd
(32) 3rd Clutch
(32) 3rd Clutch
(34) TCC Signal
(34) TCC Signal
(34) TCC Signal
(40) 4th Clutch
(40) 4th Clutch
(41) 4th Clutch Exhaust
(42) D-3
(42) D-3
(42) D-3
(42) D-3
(43) D-2
(43) D-2
(45) Low
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(46) Low-1st
(47) Reverse
(48) Reverse Servo
(49) Exhaust
(49) Exhaust
(49) Exhaust
(49) Exhaust
10/14/2010
Document ID: 44213
Page 4 of 4
(49) Exhaust
(49) Exhaust
(50) Void
(50) Void
(50) Void
(50) Void
(50) Void
(50) Void
10/14/2010
Document ID: 44189
Page 1 of 2

1996 Buick Skylark
Channel Plate Fluid Passages (Case Side)
(1) Suction
(1) Suction
(2) Line
(2) Line
(3) PRN
(3) PRN
(7) Input Clutch
(10) Modulator
(13) Release
(13) Release
(15) Cooler
(16) Lube
(28) 2nd Clutch
(28) 2nd Clutch
10/14/2010
Document ID: 44189
Page 2 of 2
(32) 3rd Clutch

(32) 3rd Clutch
(36) TCC Accumulator Feed Blow Off
(38) 4th
(42) D-3
(48) Reverse Servo
(49) Exhaust
(50) Void
(412) Cup Orificed Plug
10/14/2010
Document ID: 44205
Page 1 of 2

1996 Buick Skylark
Driven Sprocket Support Fluid Passages
(7) Input Clutch

(7) Input Clutch
(7) Input Clutch
(7) Input Clutch
(16) Lube
(16) Lube
(16) Lube
(16) Lube
(16) Lube
(16) Lube
(28) 2nd Clutch
(28) 2nd Clutch
(28) 2nd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
(40) 4th Clutch
10/14/2010
Document ID: 44205
Page 2 of 2
(40) 4th Clutch
10/14/2010
Document ID: 44216
Page 1 of 1

1996 Buick Skylark
Oil Pump Drive Shaft and Drive Sprocket Support Fluid Passages
(a) Steel Sleeve

(b) Converter Apply
(b) Converter Apply
(c)
Converter Seal Drainback
(d) Converter Release

(d) Converter Release
(227) Oil Pump Drive Shaft Assembly
(513) Oil Seal Ring (Turbine Shaft/Sleeve)
(515) Turbine Shaft To Drive Sprocket Ring (Snap)
(516) Drive Sprocket
(518) Turbine Shaft
(519) Oil Seal Ring (Turbine Shaft/Support)
(520) O-Ring Seal (Turbine Shaft/Hub) Green
(521) Drive Support/Sprocket Bearing Assembly (Drawn Cup)
(522) Drive Sprocket Support
(523) Drive Sprocket Support Bushing
10/14/2010
Document ID: 44192
Page 1 of 2

1996 Buick Skylark
Case Fluid Passages (Channel Plate Side)
(1) Suction
(1) Suction
(2) Line
(2) Line
(3) PRN
(3) PRN
(10) Modulator
(13) Release
(13) Release
(15) Cooler
10/14/2010
Document ID: 44192
Page 2 of 2

(28) 2nd Clutch
(32) 3rd Clutch
(36) TCC Accumulator Feed Blow Off
(42) D-3
(48) Reverse Servo
(49) Exhaust
(50) Void
(50) Void
(51) Vent
(52) Thermo Element
(52) Thermo Element
10/14/2010
Document ID: 44212
Page 1 of 1

1996 Buick Skylark
Case Fluid Passages (Bottom)
(1) Suction
(16) Lube
(16) Lube
(28) 2nd Clutch
(32) 3rd Clutch
(52) Thermo Element Exhaust
10/14/2010
Document ID: 44207
Page 1 of 1

1996 Buick Skylark
Accumulator Housing Fluid Passages
(16) Lube
(16) Lube
10/14/2010
Document ID: 44208
Page 1 of 1

1996 Buick Skylark
Accumulator Spacer Plate Fluid Passages
(16) Lube
(16) Lube
(16) Lube
(28) 2nd Clutch
(32) 3rd Clutch
10/14/2010
Document ID: 44209
Page 1 of 2

1996 Buick Skylark
Accumulator Cover Fluid Passages

(3) Lube Oil Pipe
(16) Lube
(16) Lube
(16) Lube
(28) 2nd Clutch
(28) 2nd Clutch
(32) 3rd Clutch
(32) 3rd Clutch
10/14/2010
Document ID: 44209
Page 2 of 2

10/14/2010
Document ID: 44206
Page 1 of 1

1996 Buick Skylark
2-1 Manual Servo Body Cover Fluid Passages

10/14/2010
Document ID: 49174
Page 1 of 2

1996 Buick Skylark
Automatic Transmission Inline Harness Connector End

View (2.4L VIN T)
Table 1:
4T60-E, C/Hcar, trans. side
Table 2:
4T60-E, Ncar (VIN T), engine side
Wiring Harness Assembly 7-way Connector, Transmission Side

8683061
Connector Part
Information
Pin
Wire Color
7-way Metri-Pack 150 Series

Black
Circuit
No.
0.8
A
Function
1-2 Shift Solenoid (1-2 SS) Valve Control
1222
BLK
0.8

1223
BLU
0.8
C
418
Torque Converter Clutch Pulse Width Modulation Solenoid

(TCC PWM Sol.) Valve Control
BLK
Torque Converter Clutch Solenoid (TCC Sol.) Valve
0.8
10/14/2010
Document ID: 49174
Page 2 of 2
TAN
422
0.8
Control
Ignition Positive Voltage
741
RED
0.8
1227
Automatic Transmission Fluid Temperature (TFT) Sensor

Input
BRN
0.8
Sensor Ground
452
GRY
Wiring Harness Assembly 7-way Connector, Engine Side

4T60-E, Ncar (VIN T), engine side
12126467
Pin
Wire Color
Black
Circuit No.
Function
1222
1-2 SS Valve Control
1223
418
TCC PWM Sol. Valve Control
422
TCC Sol. Valve Control
439
0.5
A
LT GRN
0.5
B
YEL/BLK
0.5
C
BRN
0.5
D
TAN/BLK
0.8
E
PNK
10/14/2010
Document ID: 49175
Page 1 of 2

1996 Buick Skylark
Automatic Transmission Inline Harness Connector End

View (3.1L VIN M)
Table 1:
Table 2:
4T60-E, Ncar (VIN M), engine side
Wiring Harness Assembly 7-way Connector, Transmission Side

8683061
Connector Part
Information
Pin
Wire Color

Black
Circuit
No.
0.8
A
Function
1222
BLK
0.8

1223
BLU
0.8
C
418
Torque Converter Clutch Pulse Width Modulation Solenoid

(TCC PWM Sol.) Valve Control
BLK
Torque Converter Clutch Solenoid (TCC Sol.) Valve
0.8
10/14/2010
Document ID: 49175
Page 2 of 2
TAN
422
0.8
Control
741
RED
0.8
1227
Automatic Transmission Fluid Temperature (TFT) Sensor

Input
BRN
0.8
Sensor Ground
452
GRY
Wiring Harness Assembly 7-way Connector, Engine Side

4T60-E, Ncar (VIN M), engine side
12126467
Pin
Wire Color
Black
Circuit No.
Function
1222
1223
418
TCC PWM Sol. Valve Control
422
TCC Sol. Valve Control
439
1227
TFT Sensor Signal
1057
Sensor Ground
0.5
A
LT GRN
0.5
B
YEL/BLK
0.5
C
BRN
0.5
D
TAN/BLK
0.8
E
PNK
0.5
F
YEL/BLK
0.5
G
ORN
10/14/2010
Document ID: 39554
Page 1 of 1

1996 Buick Skylark
Automatic Transmission Electronic Component Views

Electronic Component Locations
(325) Torque Converter Clutch Pulse Width Modulation Solenoid Valve

(315) 2-3 Shift Solenoid Valve (upper right)
(10) Vehicle Speed Sensor
(391) Automatic Transmission Fluid Temperature Sensor
(315) Torque Converter Clutch Solenoid Valve (lower left)
(315) 1-2 Shift Solenoid Valve (upper left)
10/14/2010
Document ID: 414087
Page 1 of 1
Stationary Windows | Schematic and Routing Diagrams | Document ID: 414087
Cell 61: Rear Defogger Relay
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2/7/2011
Document ID: 414088
Page 1 of 1
Cell 61: Rear Defogger Switch
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2/7/2011
Document ID: 414089
Page 1 of 1
Cell 61: Rear Defogger
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2/7/2011
Document ID: 363457
Page 1 of 1
Automatic Day-Night Mirrors Schematics

Cell 148
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2/7/2011
Document ID: 400567
Page 1 of 1
Stationary Windows | Component Locator | Document ID: 400567
Rear of the Vehicle
(1) Rear Window Defogger

(2) High Mounted Stop Lamp
(3) LH Tail Lamp (RH Similar)
(4) LH Tail/Stop Lamp (RH Similar)
(5) LH Tail/Stop/Turn Lamp (RH Similar)
(6) LH Backup Lamp (RH Similar)
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2/7/2011
Document ID: 343426
Page 1 of 1
Rear of the Passenger Compartment
(1) Radio Antenna Module Coil

(2) Radio Antenna Module
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2/7/2011
Document ID: 416655
Page 1 of 1
Stationary Windows Connector End Views

Radio Antenna Module (Buick)
12162414
2 Way F (BLK)
Pin
Wire Color
Circuit No.
Function
PPL
293
Rear Defogger Element Feed
DK GRN
145
Power Antenna Relay Feed - Coil
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2/7/2011
Document ID: 299960
Page 1 of 2
Stationary Windows | Repair Instructions | Document ID: 299960
Reveal Molding Replacement

Removal Procedure
1.
2.
3.
4.
5.
Remove the side reveal molding fasteners (3).

Remove the side reveal moldings (2).
Remove the drip rail molding fasteners.
Remove the drip rail moldings.
Use a flat-bladed tool in order to carefully pry the end of the windshield reveal molding (1)
out approximately 9 cm (3 in).
6. Grasp the molding with your hand. Slowly pull the reveal molding from the retainer.
7. Complete the following step if the reveal molding retainer is to be replaced.
Important: If the reveal molding retainer for the windshield is being replaced, refer to
Windshield Replacement .
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2/7/2011
Document ID: 299960
1.
2.
3.
4.
5.
6.
7.
Page 2 of 2
Apply tape in order to temporarily keep the reveal molding flush with the windshield.
Begin installation from the center of the window.
Press the reveal molding (1) into the retainer.
Install the drip rail moldings.
Install the drip rail molding fasteners.
Install the side reveal moldings (2).
Install the side reveal molding fasteners (3).
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2/7/2011
Document ID: 299961
Page 1 of 2
Rear Window Reveal Molding Replacement

Removal Procedure
Important: The rear reveal molding is removed during the rear window removal.
Remove the rear window (1). Refer to Rear Window Replacement .
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2/7/2011
Document ID: 299961
Page 2 of 2
1. Press the molding (2) on to the glass edge.

Start from the center of the window (1).
2. Install the rear window. Refer to Rear Window Replacement .
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2/7/2011
Document ID: 299962
Page 1 of 2
Windshield Side Reveal Molding Replacement

Removal Procedure
1. Remove the 4 fasteners (1).

2. Remove the side reveal molding (2).
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Document ID: 299962
Page 2 of 2
1. Install the side reveal molding (2).

2. Install the 4 screws (1).
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2/7/2011
Document ID: 307598
Page 1 of 2
Inside Rearview Mirror Replacement (With DD8 and

DC4)
Removal Procedure
Notice: Do not use tools or other objects to pry the mirror mount or the mirror away from
the windshield. Using tools may damage the mirror mount, the mirror or the windshield.
1. Disconnect the electrical connector (1) from the mirror (2).

Adjust the mirror to the full down position.
Using both hands, grasp both sides of the mirror (2) at the top.
2. Remove the mirror assembly from the button by rotating the mirror in a downward-rearward
motion.
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2/7/2011
Document ID: 307598
Page 2 of 2
1. Install the center bottom of the mirror mount against the windshield at the top of the button.
2. Slide the mount onto the button. Keep the mount parallel to the windshield.
3. As the mount begins to grip the button, apply a force against the button. Maintain a
downward force until the mount snaps onto the button with an audible click.
This operation requires at least 20 pounds of force.
4. Ensure that the mirror is securely attached to the button by adjusting the mirror in a normal
up/down and a side to side range.
6. Move the sensitivity switch lever to the MAX position. Turn the vehicle ignition OFF.
7. In low ambient light, the OFF/M/C/M letters should be illuminated. If the letters are not lit,
inspect the connectors and/or the wiring.
8. For electrochromatic mirrors, test the mirror by simulating glare. Perform the following steps:
8.1. Cover the forward facing sensor, located on the right side of the mirror back, using a
black cloth.
8.2. Hold the cloth over the sensor until the glass starts to darken to the non-reflective
stage.
8.3. Remove the cloth. The mirror returns to the clear reflective stage.
8.4. Repeat the previous 3 steps several times in order to ensure that the mirror operates
correctly.
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2/7/2011
Document ID: 511415
Page 1 of 2
Inside Rearview Mirror Replacement (Except DC4)

Removal Procedure
1. Adjust the mirror to the full down position.

With both hands, grasp both sides of the mirror at the top.
motion.
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2/7/2011
Document ID: 511415
Page 2 of 2
2. Slide the mount onto the button, keeping the mount parallel to the windshield.
3. As the mount starts to grip the button, apply a force against the button while maintaining a
4. This operation requires at least 20 pounds of force.
5. Check to make sure the mirror is securely attached to the button by adjusting the mirror in a
normal up/down and a side to side range.
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2/7/2011
Document ID: 511653
Page 1 of 2
Inside Rearview Mirror Replacement (With DD7)

Removal Procedure
1. Unplug the electrical connector from the mirror.

Adjust the mirror to the full down position.
With both hands, grasp both sides of the mirror at the top.
motion.
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2/7/2011
Document ID: 511653
Page 2 of 2
2. Slide the mount onto the button, keeping the mount parallel to the windshield.
3. As the mount begins to grip the button, apply a force against the button while maintaining a
4. This operation requires at least 20 pounds of force.
5. Check to make sure the mirror is securely attached to the button by adjusting the mirror in a
normal up/down and a side to side range.
7. Move the Sensitivity switch lever to the MAX position and turn the vehicle ignition off.
8. In low ambient light, the OFF/M/C/M letters should be illuminated. If they are not lit, check
connectors and/or wiring.
9. For Electrochromatic mirrors, test the mirror by simulating glare as follows:
10. Cover the forward facing sensor, located on the right side of the mirror back with a black
cloth.
11. Hold the cloth over the sensor until you notice the glass start to darken to the non-reflective
stage.
12. Remove the cloth and the mirror will return to the clear reflective stage.
13. Repeat the previous three steps several times to make sure the mirror operates correctly.
14. Calibrate compass if necessary. Refer to Compass Calibration Description .
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2/7/2011
Document ID: 307601
Page 1 of 2
Rearview Mirror Support Installation

The rearview mirror is attached to a support. The support is secured to the windshield glass. The
glass supplier installs the support by using a plastic-polyvinyl butyl adhesive. Replacement
windshield glass has the mirror support bonded to the glass assembly.
Removal may cause damage to the windshield. If the support becomes detached, use the
installation procedure below.
In order to install a detached mirror support or install a new part, the following items are needed:
GM P/N 1052369 LOCTITE Minute-Bond Adhesive 312 2 component pack or the equivalent
A mirror support
A wax marking pencil or a crayon
Rubbing alcohol
A clean paper towel
A fine emery cloth or sandpaper (320 or 360 grit)
A clean toothpick
1. Use a wax marking pencil or a crayon in order to mark the position of the mirror support on
the outside surface of the windshield.
If the mirror location cannot be determined by residue from the previous support, measure
and mark the windshield (1) in order to locate the bottom of the support.
2. Draw a circle around the mirror support location (3) on the outside of the window in order to
indicate the cleaning area.
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2/7/2011
Document ID: 307601
Page 2 of 2
3. Use paper towel and one of the following items in order to clean the circled area on the inside
of the window:
A scouring cleanser
A window cleaner
A polishing compound
4. In order to remove any traces of scouring powder or cleaning solution, rub the area until
completely clean.
Dry the area using an alcohol saturated paper towel.
5. Use a piece of fine grit (320 or 360) emery cloth or sandpaper in order to sand the bonding
surface of the rearview mirror support . If you are reusing the original rearview mirror
support, remove all traces of the factory installed adhesive.
6. Wipe the sanded mirror support using a clean paper towel saturated with alcohol.
Allow the support to dry.
7. In order to prepare the rearview mirror support prior to installation, follow the directions on
the manufacturer's kit.
8. Position the support onto the premarked location, placing the rounded end upward.
Press the support against the window for 30-60 seconds.
9. Exert steady pressure against the window.
After 5 minutes, use one of the following items in order to remove any excess adhesive:
An alcohol moistened paper towel
A window cleaning solution
10. Reinstall the mirror.
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2/7/2011
Document ID: 299963
Page 1 of 10
Windshield Replacement (Long Method)

Removal Procedure
Tools Required
J 39032 Stationary Glass Removal Tool
1. Remove the drip moldings.
2. Remove the side reveal molding. Refer to Windshield Side Reveal Molding Replacement .
3. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper/Washer
Systems.
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2/7/2011
Document ID: 299963
Page 2 of 10
Notice: Be sure to follow the service procedure when removing the air inlet grille panel.
Failure to follow service procedure may cause damage to the air inlet grille panel or the
windshield.
4. Remove the air inlet screen.
5. Remove the rearview mirror (3). Refer to Inside Rearview Mirror Replacement .
6. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding
Replacement in Interior Trim.
7. Remove the front sunshades. Refer to Sunshade Replacement in Interior Trim.
8. Remove the upper console fasteners, if equipped.
9. Partially lower the headliner in order for access.
Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger
compartment and cause personal injury.
10. Remove the defroster grille. Refer to Defroster Grille Replacement in Instrument Panel,
Gauges and Console.
11. From the inside of the vehicle, cut out the windshield.
Use the J 39032
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Document ID: 299963
Page 3 of 10
12. Remove the windshield, with the aid of an assistant.

13. Remove the reveal molding retainer from the windshield.
14. If you will reuse the original window (1), use a razor knife in order to remove any existing
urethane adhesive (3) from the following locations:
The window (1)
The windshield body surface (2)
Caution: Failure to prep the area prior to the application of primer may cause insufficient
bonding of urethane adhesive. Insufficient bonding of urethane adhesive may allow
unrestrained occupants to be ejected from the vehicle resulting in personal injury.
15. Clean the surface of the window where new urethane adhesive applies. Clean around the
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edge of the inside surface of the window.
2/7/2011
Document ID: 299963
Page 4 of 10
Use one of the following cleaners:

A clean isopropyl alcohol dampened cloth
GM Window Cleaner P/M 1050427 or the equivalent
1. The following components may reveal the causes of a broken windshield:
The flange of the windshield opening
The windshield reveal molding
The windshield
The acoustic strip
2. Inspect for any of the following conditions in order to prevent future breakage of the
windshield:
High welds
Solder spots
Hardened spot weld sealer
Any obstruction or irregularity in the pinchweld flange.
The acoustic strip was not installed
3. Inspect the condition of the windshield opening and the adhesive bead. Refer to Adhesive
Service Kit Description .
Tools Required
J 24811 Urethane Adhesive Dispensing Gun
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Document ID: 299963
Page 5 of 10
1. Firmly press the reveal molding retainer (4) onto the edge of the windshield (2).
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Document ID: 299963
Page 6 of 10
2. With the aid of an assistant, dry fit the window in the opening in order to determine the
correct position.
Fit the window by completing the following steps:
2.1. Position the window in the opening on top of the windshield blocks (1).
2.2. Use masking tape in order to mark the location of the window in the opening.
2.3. Slit the masking tape at the window edge. During installation, the tape on the window
aligns with the tape on the body.
2.4. Remove the window from the opening.
Place the window inside up on a clean protected surface.
3. Install the reveal molding.
4. Install the defroster grille. Refer to Defroster Grille Replacement
Notice: Failure to install the acoustic strip could cause windshield breakage.
5. Install the acoustic strip (1).
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Document ID: 299963
Page 7 of 10
Important: Prevent the Window Prep 1 (clear) from running into the vision area of the
windshield.
This primer dries almost instantly. This primer may stain the windshield if not applied evenly.
6. Use a new dauber in order to apply Window Prep 1 (clear) to the edges of the window.
7. Shake the Window Primer 2 (black) well.
8. Use a new dauber in order to apply the primer 2 (black) over the previously applied clear
primer.
Allow approximately 6-10 minutes for drying the Window Primer 2 (black).
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Document ID: 299963
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Caution: When replacing stationary windows, use Urethane Adhesive Kit GM P/N 12346392
(Canadian P/N 10952983), or a urethane adhesive system meeting GM Specification
GM3651G, to maintain original installation integrity. Failure to use the urethane adhesive kit
will result in poor retention of the window which may allow unrestrained occupants to be
ejected from the vehicle resulting in personal injury.
9. Apply a 14 mm (9/16 in) high and 8 mm (5/16 in) wide bead of urethane adhesive to the
windshield over the previously applied primers.
Use a J 24811 .
10. With the aid of a helper, install the windshield in the opening.
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Document ID: 299963
Page 9 of 10
11. Align the tape lines on the windshield and on the body surfaces.
12. Firmly press the windshield into place.
13. Tape the windshield (1,2) to the body in order to minimize movement.
14. Install the side reveal moldings (4). Refer to Windshield Side Reveal Molding Replacement
15. Install the air inlet grille screen (2).
16. Install the wiper arms. Refer to Windshield Wiper Arm Replacement in Wiper/Washer
Systems.
Important: DO NOT direct a hard stream of high pressure water at the fresh urethane
adhesive.
17. Watertest the window immediately using a soft spray.
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Document ID: 299963
Page 10 of 10
Use warm or hot water in order to accelerate the cure of the adhesive.
18. If you find a leak, use a plastic paddle in order to apply extra urethane adhesive at the leak
point.
19.
20.
21.
22.
Install the drip moldings (2).

Install the overhead console fasteners.
Install the sunshade. Refer to Sunshade Replacement in Interior Trim.
Install the windshield pillar moldings. Refer to Windshield Pillar Garnish Molding Replacement
in Interior Trim.
23. Install the rearview mirror. Refer to Inside Rearview Mirror Replacement or Rearview Mirror
Support Installation .
Important:
Partially lower a door window in order to prevent pressure build-ups when closing the
doors prior to the urethane adhesive cure.
DO NOT DRIVE THE VEHICLE until the urethane adhesive is cured.
DO NOT USE COMPRESSED AIR in order to dry the urethane adhesive.
24. Allow a minimum of 6 hours at room temperature, 22C (72F), at 30 percent relative
humidity for curing the urethane adhesive.
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2/7/2011
Document ID: 487403
Page 1 of 3
Windshield Replacement (Short Method)

Removal Procedure
1. Apply masking tape around the windshield in order to protect the painted surface of the
vehicle.
2. Remove the inside rear view mirror. Refer to Inside Rearview Mirror Replacement .
3. Lower the front of the headliner. Refer to Headlining Trim Panel Replacement .
4. Remove the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers
Washer Systems.
5. Remove the reveal moldings. Refer to Reveal Molding Replacement .
Caution: If broken glass falls into the defroster outlets, it can be blown into the passenger
compartment and cause personal injury.
6. Lubricate the cutting area prior to windshield removal.
7. Use the equalizer, refer to Special Tools from the inside of the glass in order to cut the
urethane seal.
8. With the aid from an assistant, carefully remove the windshield.

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2/7/2011
Document ID: 487403
Page 2 of 3
1. Reposition the headliner to the original position. Refer to Headlining Trim Panel
Replacement .
2.
3.
4.
5.
6.
7.
8.
Remove excessive urethane from pinch weld area.

Clean pinch weld area.
Apply pinch weld primer.
Replace the foam tape seal at the bottom side of the cowl area.
Clean the new glass.
Apply the two-part primer to the new windshield sealing surface.
Apply the urethane to the pinch weld area.
9. Carefully install the new windshield with the aid from an assistant.
10. Install the reveal moldings. Refer to Reveal Molding Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 487403
Page 3 of 3
11. Install the windshield wiper arms. Refer to Windshield Wiper Arm Replacement in Wipers
Washer Systems.
12. Clean the windshield and remove the masking tape.
13. Install the rear view mirror. Refer to Inside Rearview Mirror Replacement .
14. Water test the urethane seal.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 1 of 9
Rear Window Replacement (Long Method)

Removal Procedure
Tools Required
J 24402-A Cold Knife Glass Sealant Remover
1. Mark the center of the window.
2. Remove the upper interior quarter trim. Refer to Rear Quarter Trim Panel Replacement in
Interior Trim.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 2 of 9
3. Disconnect the rear window defogger connectors (1,2,3).
4. Pull the reveal molding (1) from the rear window. Refer to Rear Window Reveal Molding
Replacement .
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 3 of 9
Important: Use a short blade on the cold knife to avoid cutting the defroster wires.
5. Working outside of the vehicle, cut out the window.
Use a J 24402-A .
6. With the aid of an assistant, remove the rear window.

7. If you reuse the original window, use a razor knife in order to remove any existing urethane
adhesive from the window edge and from the body surface.
8. Clean the surface of the window which new urethane adhesive contacts. Clean around the
edge of the inside surface of the window.
Use one of the following cleaners:
A clean isopropyl alcohol dampened cloth
GM Window Cleaner P/M 1050427 or the equivalent
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 4 of 9
1. The following components may reveal the causes of a broken window:

The flange of the window opening
The window reveal molding
The window
2. Inspect for any of the following conditions in order to prevent future breakage of the window:
High welds
Solder spots
Hardened spot weld sealer
Any obstruction or irregularity in the pinchweld flange.
3. Inspect the condition of the window opening and the adhesive bead. Refer to Adhesive
Service Kit Description .
Tools Required
J 24811 Urethane Adhesive Dispensing Gun
1. With the aid of an assistant, dry fit the window (2) in the opening in order to determine the
correct position. Fit the window by completing the following steps:
1.1. Position the window in the opening.
1.2. Use masking tape in order to mark the location of the window in the opening.
1.3. Slit the masking tape at the window edge. During installation, the tape on the window
aligns with the tape on the body.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 5 of 9
1.4. Remove the window from the opening.

Place the window inside up on a clean protected surface.
2. Position the reveal molding (1) to the edge of the window.

3. Press the reveal molding onto the window.
Start at the center of the of the window.
Work outward.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 6 of 9
Important: Prevent the Window Prep 1 (clear) from running into the vision area of the
window.
This primer dries almost instantly. This primer may stain the window if not applied evenly.
4.
5.
6.
7.
Use a new dauber in order to apply Window Prep 1 (clear) to the edges of the window.
Immediately wipe the primed area with a clean cloth.
Shake the Window Primer 2 (black) well.
Use a new dauber in order to apply the primer 2 (black) over the previously applied clear
primer.
Allow approximately 6-10 minutes the Window Primer to dry 2.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 7 of 9
8. Apply a 14 mm (5/16 in) high and 8 mm (5/16 in) wide bead of urethane adhesive (3) to the
window.
Use a J 24811 .
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 8 of 9
9. With the aid of a helper, install the window (1) in the opening.
10. Align the tape lines on the window and the body surface.
11. Press firmly the window into place.
12. Tape the window to the body in order to minimize movement.

13. Clean any excess urethane from the body with a lint free cloth.
Important: DO NOT direct a hard stream of high pressure water at the fresh urethane
adhesive.
14. Watertest the window immediately using a soft spray.
Use warm or hot water in order to accelerate the cure of the adhesive. Refer to Water Hose
Test in Waterleaks.
15. If you find a leak, use a plastic paddle in order to apply extra urethane adhesive at the leak
point.
tomsn048@gmail.com
2/7/2011
Document ID: 299964
Page 9 of 9
16. Connect the rear window defogger connectors (1,2,3).

17. Install the upper interior quarter trim. Refer to Rear Quarter Trim Panel Replacement
Important:
Partially lower a door window in order to prevent pressure build up when closing the
doors prior to the urethane adhesive cure.
DO NOT DRIVE THE VEHICLE until the urethane adhesive is cured.
DO NOT USE COMPRESSED AIR in order to dry the urethane adhesive.
18. Allow 6 hours at room temperature, 22C (72F), at 30 percent relative humidity for curing
the urethane adhesive.
tomsn048@gmail.com
2/7/2011
Document ID: 487424
Page 1 of 2
Rear Window Replacement (ShortMethod)

Removal Procedure
1. Use masking tape in order to protect the painted surface around the rear window.
2. Remove the reveal molding. Refer to Rear Window Reveal Molding Replacement .
3. Remove the rear quarter trim panels. Refer to Rear Quarter Trim Panel Replacement in
Interior Trim.
4. Disconnect the electrical connector to the rear defogger grid and antenna (if applicable).
5. Cut the urethane with a cold knife from the exterior of the back glass.
6. With the aid from an assistant, remove the back glass.

7. Remove any excessive urethane from the pinch weld area.
8. Clean the pinch weld area.
1. Apply pinch weld primer.
2. Clean the new rear window.
3. Apply the two-part primer to the sealing edge of the new glass.
tomsn048@gmail.com
2/7/2011
Document ID: 487424
Page 2 of 2
4. Install the new reveal molding to the rear window.

5. Apply urethane to the pinch weld area.
6. With the aid from an assistant, install the new rear window.
7.
8.
9.
10.
11.
12.
Apply masking tape in order to hold the rear window in place until the urethane has cured.
Connect the electrical connector to the rear defogger grid and antenna (if applicable).
Install the rear quarter trim panels. Rear Quarter Trim Panel Replacement in Interior Trim.
Remove the masking tape from the painted surface.
Clean the new rear window and surrounding area.
Water test the urethane seal for leaks.
tomsn048@gmail.com
2/7/2011
Document ID: 280366
Page 1 of 3
Grid Line Repair

Caution: To avoid personal injury:
Do not allow the repair material to come in contact with skin or eyes and avoid breathing
vapors.
Do not use near sparks or open flame.
Important: The rear defogger repair kit GM P/N 12346001 contains all of the materials needed to
repair the rear window defogger grid lines. You may also use an equivalent repair material.
1. Disconnect the battery feed at the rear window defogger system.

2. Inspect the rear window defogger grid lines (1,3).
3. Use a grease pencil in order to mark the grid line breaks (2) on the outside of the
window (4).
4. Complete the following steps in order to prep the grid line area to be repaired:
Buff the grid line to about 6.0 mm (0.25 in) beyond each side of the break using fine steel
wool.
Wipe the area clean using a cloth dampened with alcohol.
Important:
Use a repair decal or tape strips (2) in order to control the width of the repair.
If you use a decal, ensure that the die-cut metering slot is the same width as the grid
line.
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2/7/2011
Document ID: 280366
Page 2 of 3
5. Complete one of the following steps:

Install a grid line repair decal.
Install 2 strips of tape (2).
- One positioned above the repair area.
- One positioned below the repair area.
6. Remove the clamp from the container of the grid repair material.
7. Thoroughly mix the hardener and the silver plastic.
If the hardener is crystallized, immerse the packet in hot water until the hardener liquefies.
8. Apply the grid repair material (1) to the repair area using a small plastic paddle (3) or an
equivalent.
9. Carefully remove the decal or the tape (2).
tomsn048@gmail.com
2/7/2011
Document ID: 280366
Page 3 of 3
Notice: The grid line repair material must be cured with heat. To avoid heat damage to the
interior trim, protect the trim near the repair area where heat is to be applied.
10. Using a heat gun, apply heat to the repair area:
Hold the heat gun nozzle 25 mm (1 in) from the repair surface.
Use a minimum temperature of 149C (300F).
Apply the heat for 1-2 minutes.
11. Inspect the grid line repair for appearance:
11.1. If the grid line appears to be discolored, apply a tincture of iodine to the grid line
using a pipe cleaner or a fine brush.
11.2. Allow the iodine to dry for at least 30 seconds.
11.3. Use a lint free cloth to carefully wipe off any excess iodine.
Important: Protect the trim from heat damage.
12. Allow the repair area to cure undisturbed for at least 24 hours.
13. Test the defogger operation in order to verify that the grid line is repaired.
tomsn048@gmail.com
2/7/2011
Document ID: 307616
Page 1 of 1
Rear Window Defogger Braided Lead Wire

1. You may reattach the rear defogger bus bar lead wire or terminal by resoldering.
Notice: Use only enough heat to melt the solder. Using excessive heat can damage the rear
window defogger components or the rear window.
2. Use a solder containing 3 percent silver and a rosin flux paste.
3. Before soldering the bus bar, buff the repair area with fine steel wool. This removes the oxide
coating formed during the glass manufacture.
4. Use a brush in order to apply a paste-type rosin flux in small quantities to the following
locations:
The wire lead
The bus bar repair area
5. Beforehand, coat the soldering iron tip with solder.
Use only enough heat in order to melt the solder. Use only enough solder in order to ensure
a complete repair.
6. DO NOT overheat the wire when resoldering the wire to the bus bar.
tomsn048@gmail.com
2/7/2011
Document ID: 344176
Page 1 of 1
Theft Deterrent | Schematic and Routing Diagrams | Document ID: 344176
Cell 133: PASS-Key II System
2/7/2011
Document ID: 344180
Page 1 of 1
Cell 133: Ignition Switch
2/7/2011
Document ID: 344183
Page 1 of 1
Cell 133: Content Theft Deterrent System (CTD) -- UA6
2/7/2011
Document ID: 344230
Page 1 of 1
Cell 133: RH Front Door Tamper Switch
2/7/2011
Document ID: 344231
Page 1 of 1
Cell 133: Content Theft Deterrent System (CTD) -- UA6
2/7/2011
Document ID: 344237
Page 1 of 1
Cell 133: Oldsmobile
2/7/2011
Document ID: 344245
Page 1 of 1
Cell 133: Buick
2/7/2011
Document ID: 344253
Page 1 of 1
Cell 133: Pontiac
2/7/2011
Document ID: 400606
Page 1 of 1
Theft Deterrent | Component Locator | Document ID: 400606
Passenger Compartment, Behind the Right Side of the IP
(1) Theft Deterrent Module
2/7/2011
Document ID: 515110
Page 1 of 1
RH Front Door
(1) RH Front Door (LH Similar)

(2) RH Front Door Lock Cylinder Switch (LH Similar)
(3) RH Front Door Lock Cylinder (LH Similar)
2/7/2011
Document ID: 343345
Page 1 of 1

2/7/2011
Document ID: 359879
Page 1 of 2
Theft Deterrent System Connector End Views

Table 1:
Pass-Key II Theft Deterrent Module
Table 2:
Pass-Key II Theft Deterrent Module
Connector Part
Information
12110259
16-Way F Micro - Pack 100 Series (GRN)
Pin
Wire Color
Circuit
No.
A1
RED
1642
A2
PNK
139
Fused Output - IGN
A3
DK BLU
229
Vehicle Anti-Theft System Signal - Disable Engine
A4
YEL/BLK
625
Vehicle Anti-Theft System - Starter Enable Relay

Output - Coil
A5
DK GRN
264
A6-A8
--
--
Not Used
B1
--
--
Not Used
B2
PNK
139
B3-B4
--
--
B5
BLK/WHT
251
Ground
B6
BLK/WHT
251
Ground
B7
PPL/WHT
1074
Ignition Key Resistor Return
B8
WHT/BLK
1073
Ignition Key Resistor Feed
Function
Fused Output - IGN

Not Used
2/7/2011
Document ID: 359879
Page 2 of 2
08900863
Pin
Wire Color
Circuit No.
LT BLU
263
BLK
1250
Function
Ground
2/7/2011
Document ID: 299648
Page 1 of 2
Theft Deterrent | Repair Instructions | Document ID: 299648
Theft Deterrent Module Replacement

Removal Procedure
1. Remove the instrument panel. Refer to Instrument Panel Assembly Removal .
2. Remove the fastener from the rear edge of the module.
3. Remove the PASS-Key II module from the bracket (1).

4. Disconnect the electrical connection(s).
1. Connect the electrical connection(s).
2/7/2011
Document ID: 299648
Page 2 of 2
2. Install the PASS-Key II module to the bracket (1).

3. Install the fastener.
4. Install the instrument panel. Refer to Instrument Panel Assembly Removal .
2/7/2011
Document ID: 299649
Page 1 of 2
Theft Deterrent Relay Replacement

Removal Procedure
Air bag deployment
Personal injury
2. Remove the instrument panel (IP) assembly. Refer to Instrument Panel Assembly Removal .
3. Remove the following components from the stud:

The fastener
The starter enable relay (1)
4. Disconnect the starter enable relay connector.
5. Remove the starter enable relay (1).
2/7/2011
Document ID: 299649
Page 2 of 2
1. Install the starter enable relay connector.

Position the relay (1) over the stud.
2. Install the fastener to the stud.
Tighten
3. Install the IP assembly. Refer to Instrument Panel Assembly Removal .
2/7/2011
Document ID: 299653
Page 1 of 1
Programming Additional Keys

Tools Required
J 35628-A Vats/Pass Interrogator Tester
Important: When servicing the PASS-Key II system, obtain all the vehicle ignition keys.
Verify the key code values with the J 35628-A .
1. In order to copy a PASS-Key II ignition key, determine the necessary key code or
resistance value.
2. Determine the master ignition key code using the J 35628-A as outlined in the following
procedure:
Important: Disconnect the tool wiring connectors.
2.1. Turn ON the J 35628-A .
2.2. Insert the key into the tool lock cylinder.
2.3. Note the measured key code of the master ignition key as displayed on the key code
reader.
2.4. Obtain a key blank matching the key code.
2.5. Cut the key blank to match the original key.
2/7/2011
Document ID: 299654
Page 1 of 2
Programming Replacement Keys, Ignition Cylinder, or

Powertrain Control Module
Tools Required
J 35628-A Vats/Pass Interrogator Tester
J 35628-90 Vats/Pass Harness Adapter
In order to replace lost PASS-Key II ignition keys, determine the required mechanical cut and the
key code to start the vehicle from the vehicle invoice.
If the codes are not available, use the following steps in order to determine the code:
1. Determine the mechanical cut from the following sources:
The code sticker on the steering column (ignition) lock cylinder
The original key knock outs
If the mechanical cut can not be determined, replace the steering column (ignition) lock
cylinder.
2. Using the J 35628-A and the J 35628-90 , determine the correct key code using the following
steps:
2.1. Connect the J 35628-90 (48 way) connectors to both the body harness and the
steering column harness of the steering column inline connector C202.
Important: Do not connect to the ignition lock switch.
2.2. Connect one J 35628-90 (2 way) connector to the harness side of the steering column
(ignition) lock cylinder connector.
2.3. Connect the other end of the J 35628-90 (2 way) connector to the J 35628-A .
2.4. Turn on the J 35628-A .
2.5. Place the key code switch in the number 1 position.
2.6. Start the engine with the new mechanically cut key.
If the engine starts, the key code is 1.
2.7. If the engine does not start, turn the ignition switch to the OFF position.
2.8. Press the 4 minute timer on the J 35628-A .
2.9. When the timer light turns OFF, or the START CAR message is displayed, place the J
35628-A key code switch in the next position (2, 3, 4...).
2.10. Attempt to start the engine.
If the engine starts, you have the correct key code. Proceed to the next step.
If the engine does not start, perform the previous 3 steps.
2/7/2011
Document ID: 299654
Page 2 of 2
2.11. Make a new ignition key using the correct key code and the mechanical cut.
2.12. Ensure that the new key starts the engine.
2/7/2011
Document ID: 400515
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Steering | Variable Effort Steering
| Schematic and Routing Diagrams | Document ID: 400515
Steering Assist Schematics

Cell 45
2/7/2011
Document ID: 403917
Page 1 of 1
| Component Locator | Document ID: 403917
Steering Assist Component Views

Engine, Rear Left Side
(1) Variable Steering Actuator
2/7/2011
Document ID: 412816
Page 1 of 1
| Component Locator | Document ID: 412816
Steering Assist Connector End Views

Variable Steering Actuator
Connector Part
Information
12052635
2 Way F Metric Pack 150 Series (BLK)
Pin
Wire Color
Circuit
No.
GRY
1787
Magnetic Steering Variable Assist Motor Feed - High

Effort
WHT
345
Magnetic Steering Variable Assist Motor Feed - Low

Effort
Function
2/7/2011
Page 1 of 2
| Repair Instructions | Document ID: 1234978
Steering Wheel Position Sensor or Steering Shaft Lower

Bearing Replacement
Removal Procedure
Air bag deployment
Personal injury
1. Disable the inflatable restraint steering wheel module. Refer to Disabling the SIR System in
SIR.
2. Remove the steering column from the vehicle. Refer to Steering Wheel Replacement .
3. Remove the following from the steering shaft:
3.1. boot (5)
3.2. steering shaft seal (4)
3.3. sensor retainer (3)
3.4. sensor locator (2)
Page 2 of 2
3.5. steering wheel position sensor (1), refer to Steering Wheel Position Sensor Centering .
1. Install the following onto the steering shaft:

1.1. steering wheel position sensor (1), refer to Steering Wheel Position Sensor Centering .
1.2. sensor locator (2)
1.3. sensor retainer (3)
1.4. steering shaft seal (4)
1.5. boot (5)
2. Install the steering column to the vehicle. Refer to Steering Wheel Replacement .
Page 1 of 10
Steering Wheel Position Sensor Centering

Removal Procedure
Important: Identify the type of steering wheel position sensor from the illustrations below
BEFORE removing the sensor from the steering column. Once you have identified the steering
wheel position sensor, follow the instructions listed in the removal procedure.
1. Verify the type of steering wheel position sensor.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the
right.
Important: If reusing the existing sensor, you do not have to align the sensor before
removal. Centering is not required when it is time to reinstall.
3. Remove the connector from the sensor.
4. Remove the sensor (1) from the adapter and bearing assembly.
5. To install the sensor, proceed to step 1 in the installation section.
Page 2 of 10
6. From the technicians point of view, the FRONT of the sensor will have:
foam ring (2)
pin hole (1) for centering pin (note location of pin hole)
flush rotor flange cuff (4)
Important: If reusing the existing sensor, you must make an alignment mark on the rotor
flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when
installing the sensor. A new sensor will be required if misaligned.
7.
8.
9.
10.
Make an alignment mark on the flush rotor flange cuff (3).

Remove the connector from the sensor.
Remove the sensor from the adapter and bearing assembly.
To install the sensor, proceed to step 5 in the installation section.
Page 3 of 10
raised rotor flange cuff (3)
alignment mark (2) on rotor flange cuff (3) for installation
13. Remove the sensor from the adapter and bearing assembly.
alignment mark (2) on rotor flange cuff (3) for installation
16.
17.
18.
19.
sensor clip in FRONT of the sensor

Remove the connector from the sensor.
Remove the sensor clip from the sensor.
Remove the sensor from the adapter and bearing assembly.
To install the sensor, proceed to step 13 in the installation section.
Page 4 of 10
alignment mark (2) on flush rotor flange cuff (3) for installation
alignment mark (3) on flush rotor flange cuff (4) for installation
Page 5 of 10
foam ring (1)

Important: If reusing the existing sensor, no centering of the sensor is required.

1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the
pin until the sensor is seated.
2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your
right.
From the technicians point of view, the BACK of the sensor (2) connector will be on your left.
3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into
the adapter and bearing assembly.
4. Install the connector to the sensor.
Page 6 of 10
foam ring (4)
flushed rotor flange cuff (6)
alignment mark (5) for installation
6. From the technicians point of view, the BACK of the sensor will have:
double D flats (1)
foam ring (3)
alignment tab (2) for installing into the adapter and bearing assembly.
view of the inside of the connector
Important: If reusing the existing sensor, you must align the marks on the flush rotor
flange cuff before installation. The alignment mark must stay aligned until the sensor is
seated into the adapter and bearing assembly.
If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the
pin until the sensor is seated. If the new sensor did not come with a pin installed, you must
reorder a new sensor.
Page 7 of 10
double D flats (1)
Important: If reusing the existing sensor, you must align the marks on the raised rotor
Page 8 of 10
14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D flats.
Important: If reusing the existing sensor, you must align the marks on the raised rotor
Page 9 of 10
18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for
installation. This sensor does not have double D flats.
Page 10 of 10
foam ring (6)
double D flats (1)
Document ID: 404563
Page 1 of 1
Variable Effort Steering Programming

The variable power steering system has 3 response modes. Use a scan tool and the following table
in order to select the Variable Power Steering response mode per customer request.
Action
Result
1. Connect a scan tool to the data link

connector (DLC).
2. Input vehicle information and
select Chassis.
Select Magna Steer.
Delco Bosch ABS/TCS

Magna Steer
Diagnostics
Recalibration
Select Recalibration.
Magna Steer Recalibration Procedure - Be sure

Ignition is ON Engine OFF
Press [ENTER] to Start
Press [ENTER].
Is VIN Correct?
Select YES.
Does vehicle have Magna Steer RPO # <NV8> ?
Select YES.
Recal with the FACTORY STANDARD calibration
Select NO.
Select Calibration
More Firm
Factory Calibration
Less Firm
Select the desired response mode.
Magna Steer Recalibration Procedure is complete

Press [EXIT] to Return to Menu.
Exit the scan tool.
Reprogramming is complete.
2/7/2011
Document ID: 385074
Page 1 of 1
| Bonneville, Eighty Eight, LeSabre (VIN C/H) Service Manual | Driveline/Axle |

Wheel Drive Shafts | Specifications | Document ID: 385074

Specification
Application
Metric
English
Hub Nut
160 Nm
118 Lb Ft
Inner Joint Large Seal Clamp
176 Nm
130 Lb Ft
Outer Joint Large Seal Clmp
176 Nm
130 Lb Ft
2/7/2011
Document ID: 206325
Page 1 of 1

Wheel Drive Shafts | Specifications | Document ID: 206325
GM SPO Group Numbers

Application
GM SPO Group Number
Front Wheel Drive Axle Shaft Boot Kit
6.061
Front Wheel Drive Shaft
6.055
2/7/2011
Document ID: 228865
Page 1 of 2

Wheel Drive Shafts | Visual Identification | Document ID: 228865
Disassembled Views (Halfshaft Assembly)
(1) Retaining Ring

(2) Retainer and Housing Assembly
(3) Spacer Ring
(4) Tripot Spider Assembly
(5) Spacer Ring
(6) Seal Retaining Clamp
(7) Tripot Trilobal Bushing
(8) Inboard Seal
(9) Swage Ring
(10) Halfshaft Bar
(11) Swage Ring
(12) Outboard Seal
2/7/2011
Document ID: 228865
Page 2 of 2
(13) Seal Retaining Clamp

(14) Race Retaining Ring
(15) Chrome Alloy Balls
(16) CV Joint Inner Race
(17) CV Joint Cage
(18) CV Joint Outer Race
2/7/2011
Document ID: 385323
Page 1 of 5

Wheel Drive Shafts | Repair Instructions | Document ID: 385323
Wheel Drive Shaft Replacement

Removal Procedure
Tools Required
J 2619-01 Slide Hammer
J 28733-B Front Hub Spindle Remover
J 33008 Axle Shaft Remover
Information.
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Wheel and
Tires.
3. Loosen or remove the stabilizer shaft link assembly bolt as needed. Refer to Stabilizer Shaft
Link Replacement in Steering.
4. Remove the ball joint cotter pin and nut.

Notice: Do not overextend the wheel drive shaft. Allowing the inboard joint to overextend
can cause separation of the internal components and lead to joint failure.
5. Loosen the joint using the J 36226 . The grease fitting may have to be removed from the ball
joint for tool access. If removing the right axle, turn the wheel to the left; if removing the left
axle, turn the wheel to the right.
2/7/2011
Document ID: 385323
Page 2 of 5
6. With the pry bar between the suspension support and the lower control arm, separate the
joint.
7. Remove the hub nut (2). Insert a drift or screwdriver (1) into the caliper and rotor to prevent
the rotor from turning.
2/7/2011
Document ID: 385323
Page 3 of 5
8. Disconnect the axle from the hub using the (1) J 28733-B . The hub may be partially installed
to protect the threads. Move the strut and knuckle rearward.
Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool,
because seal or bushing damage could result. Use the proper tool to separate all ball joints.
9. Using the (4) J 33008 and the (2) J 2619-01 , disconnect the drive axle from the transaxle.
2/7/2011
Document ID: 385323
Page 4 of 5
1. Inspect the tripot housing at the transmission seal surface for corrosion, if corrosion is
present, sand the surface in a rotational motion around the sealing surface with 320 grit
emery cloth until smooth.
2. Lubricate the tripot housing surface with clean transmission fluid.
3. Push the axle into the transaxle (1). Verify that the drive axle is seated by grasping the inner
joint housing and pulling. Do not pull on the drive axle shaft.
2/7/2011
Document ID: 385323
Page 5 of 5
4. Install the drive axle into the hub and bearing. Install a new hub nut (2). Insert a drift or
screwdriver (1) into the caliper and rotor to prevent the rotor from turning.
Tighten
Hub nut to 145 Nm (107 lb ft).
5. Connect the ball joint to the knuckle.
Tighten
Ball joint nut to 10 Nm (88 lb in). Then tighten an additional 120 degrees (2 flats on nut)
during which a torque of 55 Nm (41 lb ft) must be obtained.
6. Install the cotter pin. In order to align the slot in the nut, tighten nut (up to one more flat).
7. Install the stabilizer shaft link assembly. Tighten nut to 17 Nm (13 lb ft). Refer to Stabilizer
Shaft Link Replacement in Steering.
8. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Wheel and
Tires.
2/7/2011
Document ID: 229249
Page 1 of 8

Wheel Drive Shaft Inner Joint and Boot Replacement

(Inboard Assembly)
Tools Required
J 35910 Earred Clamp Tool
J 41048 Small Swage Tool
Notice: With the removal of the wheel drive shaft for any reason, the transmission sealing
surface (the tripot male/female shank of the joint) should be inspected for corrosion. If
corrosion is evident, the surface should be cleaned with 320 grit cloth or equivalent in a
rotational motion only. Do not clean with an oscillating motion. Transmission fluid may be
used to clean off any remaining debris and the joint wiped dry before installation. Corrosion
on the joint sealing surface may damage the transmission seals and cause a fluid leak.
1. Use a hand grinder in order to cut through the swage ring. Do not damage the tripot
housing (1).
2. Remove the large boot retaining clamp from the tripot joint with side cutter.
3. Dispose of the large boot retaining clamp.
Notice: Do not cut through the wheel drive shaft inboard or outboard boot during service.
Cutting through the boot
may
damage
the
sealing surface
the housing and the tripot or
2011
General
Motors
Corporation.
All rightsof
reserved.
2/7/2011
Document ID: 229249
Page 2 of 8
the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt
intrusion and premature wear of the constant velocity joint.
4.
5.
6.
7.
Separate the halfshaft inboard boot from the trilobal tripot bushing (3) at the large diameter.
Slide the boot (4) away from the joint along the halfshaft bar.
Remove the housing (1) from the tripot joint spider (2) and the halfshaft bar.
Remove the trilobal tripot bushing (3) from the housing (1).
8. Spread spacer ring (2) with the J 8059 .

9. Slide the spacer ring and tripot joint spider back on halfshaft bar (1).
10. Remove the halfshaft bar retaining ring from the groove (5) on the halfshaft bar.
11. Slide tripot joint spider assembly (2) off of the halfshaft bar.
12. Clean the following items with cleaning solvent:
The tripot balls
2/7/2011
Document ID: 229249
Page 3 of 8
The needle rollers

The housing
13. Remove all traces of old grease and any contaminates. Dry all parts.
14. Inspect the following parts for damage or wear:

The halfshaft inboard boot (4)
The tripot joint spider assembly (2)
The housing (1)
The trilobal tripot bushing (3)
The needle rollers
Assembly Procedure
2/7/2011
Document ID: 229249
Page 4 of 8
1. Place the new small boot clamp (2) onto the small end of the joint boot (1). Slide the joint
boot (1) and the small boot clamp (2) onto the halfshaft bar.
2. Position the small end of the joint boot (1) into the joint boot groove (3) on the halfshaft bar.
3. Mount J 41048 in a vise and proceed as follows:

3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048 .
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J 41048 .
3.4. Before proceeding, ensure there are no pinch points on the halfshaft inboard boot. This
could cause damage to the halfshaft inboard boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.
2/7/2011
Document ID: 229249
Page 5 of 8
4. Align the following items:
The housing
The swage ring (2)
Tighten
Tighten each bolt of J 41048 180 degrees at a time using a ratchet wrench. Alternate
between each bolt until both sides are bottomed.
2/7/2011
Document ID: 229249
Page 6 of 8
5. Install the spacer ring (2) on the halfshaft bar (1) in groove using J 8059 .
Important: Ensure that the counterbored face of the tripot joint spider (2) faces toward the
end of the halfshaft bar (4).
6. Slide the tripot joint spider assembly (2) toward the spacer ring (1) as far as it will go on the
halfshaft bar (4).
7. Install the halfshaft bar retaining ring in the groove of the halfshaft bar.
2/7/2011
Document ID: 229249
Page 7 of 8
Important: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1).
8. Place approximately half of the grease from the service kit in the halfshaft inboard boot. Use
the remainder of the grease to repack the housing.
9. Install the trilobal tripot bushing (3) to housing.
10. Position the larger new boot retaining clamp (2) on the halfshaft inboard boot.
11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar.
12. Slide the large diameter of the halfshaft inboard boot (2), with the larger clamp (3) in place,
over the outside of the trilobal tripot bushing and locate the lip of the boot in the groove.
Important: The halfshaft inboard boot must not be dimpled, stretched out or out of shape in
any way. If the halfshaft inboard boot is not shaped correctly, carefully insert a thin flat blunt
2/7/2011
Document ID: 229249
Page 8 of 8
tool (no sharp edges) between the large boot opening and the trilobal tripot bushing in order
to equalize the pressure. Shape the halfshaft inboard boot properly by hand. Remove the
tool.
13. Position the joint assembly at the proper vehicle dimension.
14. Align the following items while latching:

The tripot housing (1)
The large boot retaining clamp (2)
Tighten
Crimp the boot retaining clamp (2) with J 35910 to 176 Nm (130 lb ft). Add the breaker
bar (5) and the torque wrench (4) to the J 35910 if necessary.
2/7/2011
Document ID: 229258
Page 1 of 8

Wheel Drive Shaft Outer Joint and Boot Replacement

Tools Required
J 35910 Earred Clamp Tool
J 41048 Small Swage Tool
1. Remove the large boot retaining clamp from the CV joint with a side cutter. Discard the boot
retaining clamp.
2. Remove the small boot retaining clamp from the halfshaft bar with a side cutter. Discard the
boot retaining clamp.
3. Separate the outboard boot (5) from CV joint outer race (1) at the large diameter and slide
the boot (5) away from the CV joint along the bar (4).
4. Wipe the grease from the face of the CV joint inner race (2).
5. Spread the ears on the race retaining ring (3) using J 8059 and remove the CV joint
assembly from the bar (4).
6. Remove the boot (5) from the bar (4).
2/7/2011
Document ID: 229258
Page 2 of 8
7. Use a brass drift and a hammer to gently tap on the CV joint cage (1) until it is tilted enough
to remove the first chrome alloy ball (2).
8. Tilt cage in the opposite direction to remove the opposing ball (2).
9. Repeat this process until all six balls are removed.
10. Position the CV joint cage (4) and the CV joint inner race 90 degrees to the centerline of the
CV joint outer race (1) and align the CV joint cage windows (3) with the lands of the CV joint
outer race (2).
11. Remove the CV joint cage (4) and the CV joint inner race from the CV joint outer race (1).
2/7/2011
Document ID: 229258
Page 3 of 8
12. Rotate the CV joint inner race 90 degrees to the centerline of the CV joint cage with the lands
of the CV joint inner race (1) aligned with the windows of the CV joint cage (2).
13. Pivot the inner race into the cage window (2) and remove the inner race (1).
14. Clean the following items thoroughly with cleaning solvent:
The inner and outer race assemblies
The CV joint cage
The balls
15. Remove all traces of old grease and any contaminates.
16. Dry all the parts.
Assembly Procedure
2/7/2011
Document ID: 229258
Page 4 of 8
1. Place the new swage ring (2) onto the small end of the joint boot (1). Slide the boot (1) and
the swage ring (2) onto the halfshaft bar.
2. Position the small end of the boot (1) into the boot groove (3) on the halfshaft bar.
3. Mount theJ 41048 in a vise and proceed as follows:

3.1. Position the outboard end (1) of the halfshaft assembly in tool J 41048 .
3.2. Align the top of boot neck on the bottom die using the indicator.
3.3. Place the top half of the J 41048 on the lower half of the J 41048 .
3.4. Before proceeding, ensure there are no pinch points on the boot. This could cause
damage to the boot.
3.5. Insert the bolts (2).
3.6. Tighten the bolts by hand until snug.
2/7/2011
Document ID: 229258
Page 5 of 8
4. Align the following items:
The boot (1)
The swage ring (2)
Tighten
Tighten each bolt of theJ 41048 180 degrees at a time using a ratchet wrench. Alternate
between each bolt until both sides are bottomed.
2/7/2011
Document ID: 229258
Page 6 of 8
5. Put a light coat of grease from the service kit on the ball grooves of the inner race and the
outer race (1).
6. Hold inner race 90 degrees to the centerline of the cage (4) with the lands of the inner race
aligned with the windows of the cage and insert the inner race into the cage.
7. Hold the cage and the inner race 90 degrees to the centerline of the outer race (1) and align
the cage windows (3) with the lands of the outer race (2).
Important: Ensure that the retaining ring side of the inner race faces the halfshaft bar.
8. Place the cage (4) and the inner race into the outer race (1).
9. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing
ball.
10. Repeat this process until all six balls are in place.
11. Place approximately half the grease from the service kit inside the outboard boot and pack
the CV joint with the remaining grease.
2/7/2011
Document ID: 229258
Page 7 of 8
12. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove
on the bar.
Important: The outboard boot (1) must not be dimpled, stretched or out of shape in any
way. If the boot (1) is not shaped correctly, equalize the pressure in the boot (1) and shape
the boot (1) properly by hand.
13. Slide large diameter of the outboard boot (1) with the large boot retaining clamp (2) in place
over the outside of the CV joint outer race (3) and locate the boot lip in the groove on the CV
joint outer race (3).
14. Crimp the boot retaining clamp (1) using theJ 35910 , a breaker bar (3), and a torque
2/7/2011
Document ID: 229258
Page 8 of 8
wrench (2)
Tighten
Tighten the boot retaining clamp to 176 Nm (130 lb ft).
15. Check the gap dimension on the clamp ear. If the gap dimension is larger than shown,
continue tightening until gap dimension is reached.
2/7/2011
Document ID: 391900
Page 1 of 1
Wipers/Washer Systems | Specifications | Document ID: 391900

Specification
Application
Metric
English
Solvent Container Nuts
5 Nm
44 lb in
Transmission Screws
8 Nm
71 lb in
Wiper Motor Screws
9 Nm
80 lb in
Wiper Motor Cover Screws
3 Nm
26 lb in
2/7/2011
Document ID: 404800
Page 1 of 1
Wipers/Washer Systems | Schematic and Routing Diagrams | Document ID: 404800
Wiper/Washer System (Pulse) Schematics

Cell 91
2/7/2011
Document ID: 343072
Page 1 of 1
Wipers/Washer Systems | Component Locator | Document ID: 343072
Engine Compartment, Near the Left Strut Tower
(1) Windshield Washer Pump

(2) Windshield Washer Solvent Reservoir
(3) S128
(4) S124
(5) Windshield Washer Solvent Level Switch
2/7/2011
Document ID: 343345
Page 1 of 1

2/7/2011
Document ID: 343263
Page 1 of 1
Left Hand Rear of the Engine Compartment
(1) Windshield Wiper/Washer Module

2/7/2011
Document ID: 412804
Page 1 of 2
Wipers/Washer Systems | Visual Identification | Document ID: 412804
Wiper/Washer Connector End Views

Table 1:
Windshield Washer Pump
Table 2:
Windshield Wiper/Washer Module C1
Table 3:
Windshield Washer Pump
12052635
Pin
Wire Color
Circuit No.
Function
RED
228
Windshield Washer Pump Motor Feed
DK BLU
227
Windshield Washer Pump Motor Return
Connector Part
Information
12059569
2/7/2011
Document ID: 412804
Page 2 of 2
Pin
Wire Color
Circuit
No.
PPL
92
Windshield Wiper Motor Feed - High Speed
YEL
196
Windshield Wiper Motor Feed - Pack Switch

Controlled
BLK
1150
Function
Ground
Connector Part
Information
12059572
6 Way F Metric Pack 280 Series (BLK)
Pin
Wire Color
Circuit
No.
YEL
196
GRY
91
Windshield Wiper Relay Feed Coil
DK GRN
95
Windshield Wiper Motor Feed - Low Speed
RED
228
Windshield Washer Pump Motor Feed
DK BLU
227
Windshield Washer Pump Motor Return
PNK
94
Function
Windshield Wiper Motor Feed - Park Switch
Controlled
Windshield Washer Switch Signal
2/7/2011
Document ID: 391903
Page 1 of 4
Wipers/Washer Systems | Repair Instructions | Document ID: 391903
Windshield Washer Solvent Container Replacement

Removal Procedure
1. Remove the washer solvent from the washer solvent container.

2. Disconnect the electrical connectors from the washer pump and the solvent level sensor
switch.
3. Disconnect the hose from the washer pump.
4. Loosen the nut at thebottom

of the
washer
solvent All
container.
2011 General
Motors
Corporation.
rights reserved.
2/7/2011
Document ID: 391903
Page 2 of 4
5. Remove two nuts and the washer solvent container.
6. Remove the washer pump and seal from the container.
7. Remove the solvent level sensor switch and seal from the washer solvent container.
2/7/2011
Document ID: 391903
Page 3 of 4
Important: The tab on the solvent level sensor switch must be lined up with the slot in the
hole.
1. Install the solvent level sensor switch and seal in the washer solvent container.
Important: The new washer pump must be pushed all the way into the container seal.
2. Install the washer pump and the seal into the washer solvent container.
2/7/2011
Document ID: 391903
Page 4 of 4
3. Install the washer solvent container with three nuts.

Tighten
4. Connect the electrical connectors to the solvent level sensor switch and the washer pump.
5. Connect the hose to the washer pump.
6. Fill the washer solvent container with washer solvent.
2/7/2011
Document ID: 391904
Page 1 of 3
Windshield Wiper Arm Replacement

Removal Procedure
1. Open the hood with the wiper arms in the parked position.
2. Lift the wiper blade from the windshield and disengage the retaining latch with a screwdriver.
3. Remove the wiper arm from the wiper transmission drive shaft.
4. Remove the wiper blade
from
the wiper
if required.
Refer
to Windshield Wiper Blade
2011
General
Motors arm
Corporation.
All rights
reserved.
2/7/2011
Document ID: 391904
Page 2 of 3
Replacement .
1. Install the wiper blade if removed. Refer to Windshield Wiper Blade Replacement .
2. Position the wiper arm slightly below the stop surface of the park ramp, then press the arm
head casting fully onto the transmission drive shaft.
3. Push in the arm retaining latch.

4. Lift the replaced wiper arm over park ramp D.
5. Close the hood.
2/7/2011
Document ID: 391904
Page 3 of 3
Inspect the wiper pattern. The wiper arm should be 35-114 mm (1.375-4.5 in) from the top
of the driver's blade to the edge of the molding in the outwipe position.
l Inspect the park position. Both the wiper arms must be against the park ramps.
l The correct park position and outwipe dimensions are determined with the wipers operating
at low speed on wet glass.
2/7/2011
Document ID: 391906
Page 1 of 2
Windshield Wiper Blade Replacement

Removal Procedure
1.
2.
3.
4.
Turn the ignition switch to the ACCY position.

Set the wiper switch to the PULSE position.
Turn the ignition off when the wipers are at the innerwipe position and not moving.
Remove the wiper blade from the wiper arm by pushing down on the release latch and
pulling the wiper blade from the wiper arm.
2/7/2011
Document ID: 391906
Page 2 of 2
Important: Use only 22-inch beam-type blades. With the windshield wipers at the innerwipe
position, the blades must be installed with the wiper blade element notches pointed toward
the head casting of the wiper arm.
1. Install the wiper blade from the wiper arm.
2. Operate the wipers and check for proper operation.
2/7/2011
Document ID: 391908
Page 1 of 2
Wiper Blade Element Replacement

Removal Procedure
Important: The wiper blade element must be replaced if removed from the wiper blade.
1. Remove the wiper blade from the wiper arm. Refer to Windshield Wiper Blade Replacement .
2. Remove the wiper blade element by pulling out through the wiper blade claws.
2/7/2011
Document ID: 391908
Page 2 of 2
1. Install the wiper blade element into the wiper blade by sliding the wiper blade element
through the wiper blade claws until the claw is locked into the notches in the wiper blade
element.
Important: Be sure the wiper blade element is secure in all the claw sets and that the
element moves back and forth freely as the wiper blade flexes.
2. Install the wiper blade onto the wiper arm. Refer to Windshield Wiper Blade Replacement .
3. Operate the wipers and check for proper operation.
2/7/2011
Document ID: 391909
Page 1 of 3
Windshield Wiper Motor Cover Replacement

Removal Procedure
1. Disconnect the electrical connectors from the cover and the wiper motor.
2. Remove three screws.

3. Remove the wiper motor cover.
2/7/2011
Document ID: 391909
Page 2 of 3
Important: Always install the cover with the wiper motor in the park position and the drive
pin in the open area of the cam.
1. Install the wiper motor cover.
2. Install three screws.
Tighten
Tighten the screws to 3Nm (26 lb in).
2/7/2011
Document ID: 391909
Page 3 of 3
3. Connect the electrical connectors onto the cover and the wiper motor.
2/7/2011
Document ID: 391910
Page 1 of 4
Windshield Wiper Motor Replacement

Removal Procedure
Tools Required
J 39232 Wiper Transmission Separator
1.
2.
3.
4.
Remove the wiper arm and blades. Refer to Windshield Wiper Arm Replacement .
Disconnect the washer hose.
Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement
Remove the transmission drive link socket from the wiper motor crank arm using the J 39232
Wiper Transmission Separator.
2/7/2011
Document ID: 391910
Page 2 of 4
5. Disconnect the electrical connectors from the wiper motor.
6. Remove three screws.

7. Remove the wiper motor and the seal while guiding the crank arm through the hole.
Tools Required
J 39529 Wiper Transmission Installer
2/7/2011
Document ID: 391910
Page 3 of 4
1. Install the wiper motor and the seal while guiding the crank arm through the hole.
2. Install three screws.
Tighten
2/7/2011
Document ID: 391910
Page 4 of 4
3. Connect the electrical connectors to the wiper motor.
4. Install the transmission drive link socket to the wiper motor crank arm ball using the J 39529
Wiper Transmission Installer. Be sure the socket is fully seated on the ball.
5. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
6. Install the wiper arms and blades. Refer to Windshield Wiper Arm Replacement .
2/7/2011
Document ID: 391911
Page 1 of 2
Wiper Motor Park Switch Replacement

Removal Procedure
1. Remove the wiper motor. Refer to Windshield Wiper Motor Replacement .

Important: If the wiper motor is in the park position, operate the wiper motor as required to
remove the pawl from the relay slot.
2. Remove the wiper motor cover. Refer to Wiper Motor Cover Replacement .
3. Remove the screw and the park switch.
2/7/2011
Document ID: 391911
Page 2 of 2
1. Install the new park switch and the screw.

2. Operate the wiper motor back into the park position (pawl in the relay slot).
3. Install the wiper motor cover. Refer to Wiper Motor Cover Replacement , and follow the
procedure carefully.
4. Install the wiper motor. Refer to Windshield Wiper Motor Replacement .
2/7/2011
Document ID: 391912
Page 1 of 5
Windshield Wiper Transmission Replacement

Removal Procedure
Tools Required
J 39232 Wiper Transmission Separator
1. Remove the wiper arm and blades. Refer to Windshield Wiper Arm Replacement .
2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
3. Disconnect the transmission drive link sockets from the wiper motor crank arm and the
transmission drive shafts using the J 39232 Wiper Transmission Separator.
2/7/2011
Document ID: 391912
Page 2 of 5
4. Remove six screws.
5. Remove the transmission drive shafts and drive links by guiding them through the access
hole in the shroud upper panel.
Tools Required
J 39529 Wiper Transmission Installer
2/7/2011
Document ID: 391912
Page 3 of 5
1. Install the transmission drive shafts by positioning them in the plenum chamber through the
shroud upper panel openings.
2. Install the drive links on the drive shafts using the J 39529 Wiper Transmission Installer.
2/7/2011
Document ID: 391912
Page 4 of 5
3. Install the transmission with the drive shafts positioned through the drive shaft clearance
holes.
4. Install six screws.
Tighten
Important: The socket must be fully seated on the ball.

5. Install the transmission drive link socket to the wiper motor crank arm ball using the J 39529
Wiper Transmission Installer.
2/7/2011
Document ID: 391912
Page 5 of 5
6. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement .
7. Install the wiper arms. Refer to Windshield Wiper Arm Replacement .
2/7/2011
Document ID: 391913
Page 1 of 1
Wiper Chatter Repair

Some vehicles may exhibit a condition where the windshield wipers chatter and/or wipe unevenly.
Several items may contribute to this condition. To completely repair this condition, ALL the items
listed below should be checked and repaired as necessary.
Windshield Glass Cleaning
Blade Element Cleaning
Wiper Arm Pressure Check
Blade Element Set Check
2/7/2011
Document ID: 391914
Page 1 of 1
Windshield Glass Cleaning

Clean the windshield with windshield cleaner, GM P/N 1050011 or equivalent. The cleaner used
should be one which will not harm paint finish or scratch glass. The glass is clean when water no
longer beads, but sheets across the entire glass surface.
2/7/2011
Document ID: 391927
Page 1 of 1
Wiper Blade Element Cleaning

Lift each blade off of the windshield and clean the element with a cloth saturated in full strength
washer solution. Rinse blades with water.
2/7/2011

1997 Buick LeSabre Service Repair Manual

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1998 Buick Park Avenue

1998 Buick Park Avenue

Fig. 1: Locating Engine Codes

Hydraulic valve lifters are used. No valve adjustment is required.

To trouble shoot mechanical engine components, see appropriate

1998 Buick Park Avenue

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

CAUTION: If air was introduced into hydraulic system during

1998 Buick Park Avenue

servicing, bleed system. Aerated fluid, which appears Light

1998 Buick Park Avenue

refrigerant recovery/recycling equipment. Relieve fuel pressure. See FUEL

1998 Buick Park Avenue

On supercharged engine VIN 1), supercharger acts as an upper

Removal (All Except "F" Body)

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative

1998 Buick Park Avenue

bolts, upper intake manifold and gasket.

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative

1998 Buick Park Avenue

1998 Buick Park Avenue

1998 Buick Park Avenue

Fig. 4: Lower Intake Manifold Bolt Tightening Sequence - "F" Body

1998 Buick Park Avenue

Not all components need to be removed on all models. Remove

Removal & Installation (Left -All Except "F" Body)

1998 Buick Park Avenue

specification. See TORQUE SPECIFICATIONS .

Whenever right exhaust manifold pipe is removed, inspect EGR

1998 Buick Park Avenue

1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect negative

Not all components need to be removed on all models. Remove

Removal (All Except "F" Body)

1998 Buick Park Avenue

1998 Buick Park Avenue

Fig. 6: Cylinder Head Bolt Tightening Sequence

1998 Buick Park Avenue

Fig. 7: Removing Front Cover

1998 Buick Park Avenue

Fig. 8: Checking Crankshaft Balancer Clearance

If balance shaft has been moved, ensure alignment is correct

1998 Buick Park Avenue

1998 Buick Park Avenue

Fig. 9: Exploded View Of Timing Chain & Sprockets

1998 Buick Park Avenue

Not all components need to be removed on all models. Remove

1998 Buick Park Avenue

Fig. 10: Exploded View Of Rocker Arm & Components

1998 Buick Park Avenue

Balance shaft removal procedure provided by manufacturer is

1. Disconnect negative battery cable. Remove engine. See ENGINE . Remove

1998 Buick Park Avenue

Hammer (J-6125-lB), remove balance shaft from front of engine.

Balance shaft and bearings are serviced as a complete

Replace components if damaged or not within specification. See BALANCE SHAFT

BALANCE SHAFT SPECIFICATIONS

1998 Buick Park Avenue

Bearing Bore I.D.