Chevrolet - Cavalier - Workshop Manual - 2004 - 2004

Factory Workshop Manual Make Chevrolet Model Cavalier Engine and year L4-2.2L VIN F (2004) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams Accessory Delay Module: Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 7 Retained Accessory Power (RAP) Diagram 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 8 Accessory Delay Module: Description and Operation SERIAL DATA CONTROLLED RETAINED ACCESSORY POWER, RAP Retained accessory power, RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The Audio system on this vehicle is the only device that is controlled by RAP. SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER, RAP The Radio receives a RAP message from the Body Control Module, BCM over the serial data circuits. The BCM module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM module then sends a message to the Radio telling it that it is in RAP power mode. RAP will end when one of the following conditions are met: The BCM module receives an input from the drivers door jam switch. - The BCM module receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM module detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM module then sends a serial data message to the Radio ending the RAP function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11 Steps 3-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 12 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Retained Accessory Power (RAP) - Inoperative RETAINED ACCESSORY POWER (RAP) INOPERATIVE DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module , BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 13 Steps 1-5 Retained Accessory Power (RAP) - On After Timeout RETAINED ACCESSORY POWER (RAP) ON AFTER TIMEOUT DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module, BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 14 Steps 1-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 15 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Use the Scan Tool Data Display Values and Definitions Information in order to assist in diagnosing vehicle malfunctions. Compare the vehicles actual scan tool data with the typical data display value table information. Use the data information in order to aid in understanding the nature of the problem when the vehicle does not match with the typical data display values. The scan tool data values were taken from a known good vehicle under the following conditions: - The ignition switch is in the ON position. - The engine is not running. - The vehicle is in PARK. Accessory: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or ACCY position. Battery Voltage: This voltage value refers to the battery system voltage. Driver Door Ajar Sw.: The scan tool displays On/Off. On is displayed when the driver door is open, Off when closed. Ignition 1: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or CRANK position. Key In Ignition: This information refers to whether or not the ignition key is inserted into the ignition switch. The BCM uses this data to perform chime functions. ON is displayed when the key is inserted into the ignition switch. Passenger Door Ajar Sw.: The scan tool displays On/Off. On is displayed when at least one passenger door is open, Off when all passenger doors are closed. Scan Tool Data List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 24 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 26 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 27 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 28 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 29 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 30 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 31 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 32 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 33 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 34 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 35 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 36 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 37 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 38 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 39 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 40 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 41 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 42 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 43 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 44 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 45 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 46 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 47 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 48 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 49 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 50 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 51 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 52 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 53 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 54 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 55 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 56 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 57 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 63 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 68 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 73 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 74 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 80 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 89 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 90 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 91 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 92 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 93 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 94 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 95 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 96 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 97 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 98 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 99 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 100 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 101 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 102 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 103 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 104 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 105 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 106 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 107 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 108 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 109 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 110 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 111 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 112 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 113 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 114 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 119 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 120 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 121 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 122 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 123 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 124 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 125 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 126 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 127 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 128 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 129 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 130 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 131 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 132 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 133 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 134 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 135 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 136 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 137 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 138 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 139 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 140 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 141 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 142 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 143 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 144 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 145 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 146 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 147 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 148 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 149 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 150 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 151 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 152 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 157 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 158 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 159 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 160 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 161 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 162 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 163 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 164 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 165 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 166 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 167 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 168 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 173 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 186 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 191 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 192 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 198 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 207 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 208 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 209 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 210 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 211 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 212 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 213 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 214 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 215 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 216 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 217 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 218 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 219 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 220 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 221 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 222 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 223 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 224 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 225 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 226 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 227 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 228 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 229 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 230 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 231 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 232 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 237 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 238 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 239 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 240 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 241 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 242 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 243 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 244 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 245 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 246 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 247 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 248 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 253 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 266 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 271 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 272 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 282 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 283 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 284 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 285 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 286 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 287 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 288 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 289 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 290 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 291 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 292 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 293 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 294 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 295 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 296 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 297 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 298 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 299 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 300 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 301 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 302 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 303 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 304 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 305 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 306 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 307 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 312 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 313 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 314 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 315 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 316 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 317 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 318 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 319 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 320 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 321 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 322 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 323 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 324 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 325 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 326 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 327 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 328 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 329 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 330 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 331 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 332 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 333 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 334 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 335 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 336 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 337 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 338 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 339 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 340 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 341 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 342 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 343 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 344 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 345 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 350 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 351 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 352 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 353 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 354 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 355 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 356 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 357 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 358 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 359 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 360 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 361 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 366 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Disable the SIR. 2. Remove the passenger inflatable restraint module. 3. Remove the I/P carrier bolts on the passenger side. 4. Remove the bolt (1) for the module bracket strap (7). 5. Remove the module bracket strap (7) from the mounting bracket (3). 6. Slide the module (2) upward in the mounting bracket. IMPORTANT: The generation 5 module uses four connector cavities. In addition, the STID and the ESN information on the generation 5 label can not be used to update the customer account information if the module is replaced. Use a scan tool to access this information. 7. Disconnect all the electrical connector (3) from the communication interface module (1). 8. Disconnect all the coaxial cable connectors (4) from the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 378 9. Pull downward on the back of the I/P compartment to remove the OnStar(R) module (2) from the bracket (3). 10. Remove the module (2) through the opening for the passenger inflator module. INSTALLATION PROCEDURE 1. Install the OnStar(R) module (2) thorough the opening for the passenger inflator module. 2. Pull downward on the back of the I/P compartment to install the module to the bracket (3). 3. Slide the unit upward in the mounting bracket. 4. Connect the electrical connectors (3) to the module (1). 5. Connect the coaxial cable connectors (4) to the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 379 6. Reposition the module (2) in the bracket. 7. Install the module bracket strap (7) to the mounting bracket (3). 8. Install the bolt (1) for the module bracket strap (7). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 9. Install the I/P bolts on the passenger side. Tighten Tighten the bolt to 2.3 N.m (20 lb in). 10. Install the passenger inflatable restraint module. 11. Enable the SIR. 12. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 13. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 14. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 15. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 15.1. Tell the advisor that this vehicle has received a new VCIM. 15.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 15.3. Follow any additional instructions from the OnStar(R) advisor. 15.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. 16. The default language for voice recognition in the generation 5 OnStar(R) module is English. To change the language resident in the module, refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 388 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 389 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 390 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 396 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 397 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 398 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations Right Front I/P Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 403 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Service and Repair Power Door Lock Relay: Service and Repair LOCK RELAY REPLACEMENT - POWER DOOR REMOVAL PROCEDURE 1. Remove the passenger carpet retainer. 2. Remove enough of the carpet to access the door lock relay (1) located on the passenger hinge pillar (2). 3. Pull the relay (1) away from the hinge pillar (2) disengaging the rosebud retainer. 4. Disconnect the electrical connector (3) from the relay (1). 5. Remove the relay (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the relay (1) into the vehicle. 2. Connect the electrical connector (3) to the relay (1). 3. Attach the rosebud retainer on the relay (1) to the hinge pillar (2). 4. Install the carpet to a desired appearance. 5. Install the passenger carpet retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 410 Sunroof / Moonroof Module: Diagrams Sunroof Control Module, C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 411 Sunroof Control Module C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 412 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Close the sunroof. 2. Remove the headliner. 3. Remove the tie wraps securing the power sunroof control module wire harness to the drive and return tubes. 4. Release the retainers for the power sunroof control module by sliding the control module (2) towards the middle of the vehicle. 5. Disconnect the wire harness electrical connectors from the power sunroof control module (2). INSTALLATION PROCEDURE 1. Connect the wire harness connectors to the power sunroof control module (2). 2. Engage the power sunroof control module retainers by sliding the control module (2) towards the left side of the vehicle. 3. Install the tie wraps to secure the power sunroof control module wire harness to the drive and return tubes. 4. Install the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position 2. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material. 3. Disengage the electrical Connector Position Assurance (CPA) locking tab (1) from the connector sliding cover lock tab. 4. Depress the cover lock tab, then move the sliding connector cover (2) to the open position. 5. Disconnect the electrical harness connector (4) from the EBCM (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Page 417 6. Remove the 4 EBCM-to-BPMV retaining bolts. Important: ^ Do not pry apart the EBCM (1) from the BPMV (2) using a tool. Be careful not to damage seal on the EBCM or the mating surface of the BPMV. ^ Care must be taken not to damage the solenoids when the EBCM is removed from the BPMV. 7. Separate the EBCM (1) from the BPMV (2) by carefully pulling apart. Installation Procedure 1. Clean the sealing surface of the BPMV, with denatured alcohol and a clean shop cloth. 2. If the EBCM that was removed is being reinstalled, clean the seal and sealing surface of the EBCM, with denatured alcohol and a clean shop cloth. 3. Install the EBCM (1) to the BPMV (2). Use care when aligning the EBCM to the BPMV electrical terminals. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 EBCM-to-BPMV retaining bolts. Tighten the bolts in a cries-cross pattern. ^ Tighten the bolts to 5 Nm (44 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Page 418 5. Connect the electrical harness connector (4) to the EBCM (3). 6. Depress the cover lock tab, then move the sliding connector cover (2) to the home position to lock. 7. Engage the electrical connector CPA locking tab (1) to the connector sliding cover lock tab. Important: Do NOT start the engine, but only turn the ignition switch to the ON position. 8. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay. Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay. 2. Install the underhood electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 427 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 428 Cruise Control Module (CCM) Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 429 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT (2.2L L61) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector (1) from the cruise control module. 3. Open the throttle body cam slightly. 4. Disconnect the cruise control cable from the throttle body cam lever. 5. Remove the cruise control cable from the throttle body bracket. 6. Remove the cruise control cable from the retainer clip on the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 430 7. Disconnect the cruise control cable from the cruise control module by turning the cable 1/4 turn counterclockwise. 8. Disconnect the cruise control cable slug from the ribbon buckle. 9. Remove the bolts (1) from the cruise control module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 431 10. Remove the bolt and nut (1) from the cruise control module mounting bracket. 11. Remove the cruise control module from the engine compartment. INSTALLATION PROCEDURE 1. Position the cruise control module to the mounting bracket. 2. Install the bolts (1) to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to the cruise control module to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 432 3. Position the cruise control module to the engine compartment. 4. Install the bolt and nut (1) to the cruise control module mounting bracket. Tighten Tighten the nuts to the cruise control module to 10 N.m (89 lb in). 5. Connect the cruise control cable slug to the ribbon buckle. IMPORTANT: The ribbon must not be twisted. 6. Insert the cruise control cable into the cruise control module until the seal touches the module. 7. Position the narrow cable tab into the narrow slot and the wide tab into the wide slot. 8. Connect the cruise control cable to the cruise control module by turning the cable clockwise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 433 IMPORTANT: The adjuster tab must be pointing toward the front of the car after installation. 9. Connect the electrical connector to the cruise control module. 10. Install the cruise control cable to the throttle body bracket pressing into place until fully seated. 11. Open the throttle body cam slightly. 12. Connect the cruise control cable to the throttle body cam lever. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the blower motor relay from the electrical center. INSTALLATION PROCEDURE 1. Install the blower motor relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE 1. Install the A/C compressor control relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Headlamp, Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 445 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 449 Horn Relay Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 455 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 458 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 459 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 460 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 461 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 462 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) Body Control Module: Description and Operation Body Control Module (BCM) BODY CONTROL MODULE The various BCM input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The Body Control Module functions include the following. - Retained Accessory Power, RAP, Audio System only. - A/C compressor request. - Remote Function Control. - A/C cooling Fan. - Exterior and interior lighting control Daytime running lights (DRL) - Automatic lighting control - Fog lamps - Interior lighting. - Battery rundown protection (Inadvertent Power). - Chimes. Key In Ignition - Head Lamps On - Seat Belt Not Fastened - Turn Signal On - Park Brake Warning - Door Ajar Warning - Check gauges - Gauge control. - Instrument cluster indicator control. - Theft deterrent. - Engine coolant level sensing. - Key-in-ignition sensing. - Brake fluid level sensing. - Parking brake state sensing. - Rear compartment interface. - Horn interface. - Door lock interface. - Bulb Check. - ETS -Pontiac Only. - A/T Shift lock control. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 470 Body Control Module: Description and Operation Content Theft Deterrent (CTD) CONTENT THEFT DETERRENT (CTD) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 471 Body Control Module: Description and Operation Vehicle Theft Deterrent (VTD) CONTENT THEFT DETERRENT (CTD) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. The body control module (BCM) must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the SPECIAL FUNCTIONS menu on the scan tool to program the BCM. Select NEW BCM SETUP and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passlock Learn Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passlock Learn procedure. Perform the Learn Procedure if any of the following components have been replaced: The body control module (BCM) - The Passlock sensor - The powertrain control module (PCM) IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 474 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Release the body control module (BCM) wire harness retainer from the BCM bracket. 3. Disconnect the BCM electrical connectors from the BCM. 4. Release the lock tabs and remove the BCM from the BCM bracket. 5. Remove the BCM bracket nuts (2) if required. 6. Remove the BCM bracket (1) as an assembly if required. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 475 1. Install the BCM bracket (1) as an assembly if required. 2. Install the BCM bracket nuts (2) if required. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Install the BCM into the BCM bracket until lock tabs are fully seated. 4. Connect the BCM electrical connectors to the BCM. 5. Install the BCM wire harness retainer to the BCM bracket. 6. Connect the negative battery cable. 7. Reprogram the BCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 480 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 481 Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 482 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 483 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 484 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description & Function POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function > Page 487 Engine Control Module: Description and Operation Powertrain Control Module (PCM)/Theft Deterrent Control Module POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 488 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first in order to verify the PCM is the correct part. DTC P0602 indicates the EEPROM programming has malfunctioned. When DTC P0602 is set, re-program the EEPROM. 1. Disconnect the negative battery cable. 2. Push down the locking tab and pull up on the release lever and disconnect the PCM harness connectors (1). NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Press the PCM retaining tab. 4. Lift the PCM (2) from the PCM bracket (3). INSTALLATION PROCEDURE Remove the new PCM from the packaging and inspect the service number to verify the number is the same number, or an updated number, as the faulty PCM. 1. Push the PCM (2) into the PCM bracket (3). The retaining tab will lock in place. 2. Install the PCM harness connectors (1) and lock down the release levers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 489 NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning IMPORTANT: The replacement PCM must be reprogrammed and the crankshaft position system variation learn procedure must be performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 494 Ignition Control Module (ICM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 495 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS 1. Ignition Control Module (ICM) 2. Compression Sense Ignition (CSI) Pickup 3. Not Used 4. 2-3 Coil Control 5. Ignition Voltage 6. 1-4 Coil Control 7. Not Used 8. Interconnect Each ignition coil is responsible for supplying secondary energy to a pair of spark plugs. The ignition control signals output by the PCM are amplified by the ICM in order to fire each coil. The spark events are triggered by the ICM, but the module has no influence on spark timing. The ICM is also responsible for detecting and supplying a camshaft position (CMP) signal pulse to the PCM to be used for sequential fuel injection. This ignition system does not use a conventional CMP sensor that detects valve train position. The ICM detects when either cylinder 1 or cylinder 3 has fired on the cylinders compression stroke using sensing circuitry integrated within each coil. The sensing circuit detects the polarity and the strength of the secondary voltage output, the higher output is always at the event cylinder. The ICM sends a CMP signal to the PCM based on the voltage difference between the event and waste cylinder firing energy. This system is called compression sense ignition. By monitoring the camshaft position and crankshaft position (CKP) signals the PCM can accurately time the operation of the fuel injectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 496 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the accelerator cable from the bracket. 3. Remove the accelerator cable bracket bolt. 4. Remove the accelerator cable bracket. 5. Disconnect the ignition control module (ICM) harness connector. 6. Remove the ICM retaining screws. 7. Remove the ICM from the ignition coil housing. INSTALLATION PROCEDURE 1. Install the ignition control module in the ignition coil housing. IMPORTANT: Make sure the interconnect and seal are lined up before module installation. 2. Install the ICM retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 1.5 N.m (13 lb in). 3. Connect the ICM harness connector. 4. Install the accelerator cable bracket. 5. Install the accelerator cable bracket bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 497 NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 10 N.m (18 lb in). 6. Install the accelerator cable to the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Inflatable Restraint Modules And SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 502 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 503 Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 504 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 505 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 506 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 507 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM utilizes internal sensors along with the electronic frontal sensor (EFS), mounted left of the hood latch. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that Ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 508 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the connector position assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 509 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (1) horizontally to the floor pan (3). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: If the old mounting fasteners are damaged, refer to the additional repair procedures at the end of this step. Tighten Tighten the fasteners to 14 N.m (124 lb in). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) studs and/or fasteners are damaged to the extent that the SDM can no longer be properly mounted. First Repair 4.1. Discard the old fastener. 4.2. Use a new fastener GM P/N 10156138. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 14 N.m (124 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 510 Second Repair 4.1. Discard the old fastener. 4.2. Use a larger fastener GM P/N 10267482 with washer GM P/N 11500305. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 15 N.m (11 lb ft). 5. Install the SDM wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. 10. If you replaced the SDM, perform the following procedure in order to update the BCM with the new SDM part number: 10.1. Install a scan tool. IMPORTANT: The AIR BAG indicator may remain ON after the SDM is replaced. After programming the SDM part number into the BCM, cycle the ignition switch OFF and ON. This turns OFF the AIR BAG indicator and clears the DTC. 10.2. Select the Special Functions option from the SIR Menu and press enter. 10.3. Select the Setup SDM Part Number in BCM option and press enter. 10.4. Follow the procedure on the scan tool display. 10.5. Cycle the ignition switch OFF and ON. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock(TM) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Page 526 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 538 Door Lock Switch - Front Passenger With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 539 Door Lock Switch - Driver Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 540 Door Lock Switch - Front Passenger Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures POWER DOOR LOCK SWITCH REPLACEMENT REMOVAL PROCEDURE 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. INSTALLATION PROCEDURE 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 543 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement Removal Procedure 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. Installation Procedure 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Driver Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 547 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 548 Outside Rearview Mirror Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). INSTALLATION PROCEDURE 1. Install the switch (2) to the trim panel (1). 2. Begin tightening the set screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 551 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Removal Procedure 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). Installation Procedure 1. Install the switch (2) to the trim panel (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Begin tightening the set screw (3). Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation SUNROOF LIMIT SWITCHES The sunroof limit switches track the position of the sunroof glass through two limit switches: - Soft Stop limit switch through the sunroof limit switch soft stop signal circuit - Vent Stop limit switch through the sunroof limit switch range signal circuit The sunroof control module monitors the limit switches and based on the input combinations, determines the position of the sunroof glass. As a sunroof limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module monitors both sunroof switch input requests and based on the sunroof limit switch input combinations, will control an output to the sunroof motor, to drive the sunroof glass to the requested position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Dome Lamp And Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 558 Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 561 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. Installation Procedure 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 565 Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 566 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool to release the retaining tabs for the rear compartment lid switch. Remove the switch from the Instrument Panel (IP) carrier. 2. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the switch to the IP carrier. Press the switch until the retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Carefully remove the instrument panel dimmer switch bezel from the dash. 2. Disconnect the electrical connector from the traction control switch. 3. Remove the traction control switch from the instrument panel dimmer switch bezel. To avoid damage to the instrument panel dimmer switch bezel, use a flat bladed tool on the back side of the traction control switch to release the retaining clips. Installation Procedure 1. Install the traction control switch to the instrument panel dimmer switch bezel. 2. Connect the electrical connector to the traction control switch. 3. Align the instrument panel dimmer switch bezel to the dash and carefully press the retaining clips into the correct mounting areas on the dash. 4. Verify the repair. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: Customer Interest ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 582 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 588 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation Fuel Pump Pickup Filter: All Technical Service Bulletins Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 594 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 595 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 596 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 602 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 603 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Speed Sensor: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 604 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 605 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the front wheel speed sensor. 3. Remove the wheel speed sensor retaining bolt. 4. Remove the wheel speed sensor from the steering knuckle. If the sensor will not slide out of the knuckle perform the following steps: 4.1. Remove the brake rotor to access the other side of the knuckle. 4.2. Using a blunt punch, or equivalent tool, push the sensor from the outboard side of the knuckle. 5. Inspect the removed wheel speed sensor and the steering knuckle to ensure that the sensor's locating pin has not broken off in the locating hole of the knuckle. If the locating pin remains in the locating hole of the knuckle, perform the following steps. 5.1. Remove the brake rotor, if it has not already been removed, to access the other side of the knuckle. 5.2. Using a blunt punch, or equivalent tool, remove the broken locating pin from the outboard side of the knuckle. 5.3. If necessary, clean the locating hole in the knuckle using sand paper wrapped around a screwdriver, or other suitable tool. Never attempt to enlarge the hole. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 606 1. Install the front wheel speed sensor to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front wheel speed sensor retaining bolt. ^ Tighten the bolt to 12 Nm (107 inch lbs.). 3. Connect the electrical connector to the front wheel speed sensor. 4. Lower the vehicle. 5. Perform the Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 611 Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 616 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 617 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 618 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 623 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments CLUTCH RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard. The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 4.1. The release switch (1) 4.2. The stoplamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 627 Clutch Switch: Service and Repair CLUTCH RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. 4. Install the left instrument panel insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control ON/OFF Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 635 Oil Pressure Sender: Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 636 Crankshaft Position Sensor,Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 637 Engine Oil Pressure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 638 Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 639 Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 640 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the engine oil pressure sensor electrical connector. 4. Remove the engine oil pressure sensor. Installation Procedure 1. Install the engine oil pressure sensor. 2. Connect the engine oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Right Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 645 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 646 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connection from the sensor. 2. Remove the A/C refrigerant pressure sensor. Discard the O-ring seal. IMPORTANT: The sensor is mounted on a service fitting. Do not discharge the system. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sensor to 5 N.m (44 lb in). 3. Connect the electrical connection to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams I/P Dimmer Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 651 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the dimmer lamp switch using a small flat-bladed tool. 5. Remove the dimmer lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the dimmer lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the to the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 656 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 657 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 660 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 661 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 662 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 663 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 664 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 667 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 668 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 669 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 673 Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 674 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 675 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 676 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 684 Backup Lamp Switch (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 685 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Disconnect the backup lamp connector. 2. Remove the backup light switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 686 1. Install the backup light switch using pipe sealant GM P/N 1052080 or equivalent. Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 690 Brake Light Switch: Diagrams Stop Lamp Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 691 Stop Lamp Switch C2 (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 692 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT The stop lamp switch is self adjusting when properly installed. The switch does not need any further adjustment. Refer to Stop Lamp Switch Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 693 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the lower I/P trim insulator screw. 2. Remove the lower I/P trim insulator from the brake pedal bracket. 3. Disconnect the electrical connections (3, 4) from the stop lamp switch (5). 4. Rotate the stop lamp switch (5) counterclockwise until the travel stop has been reached. 5. Pull the stop lamp switch (5) rearward. 6. Remove the stop lamp switch (5) from the brake pedal bracket (1). INSTALLATION PROCEDURE 1. Install the stop lamp switch (3) into the retainer (2). IMPORTANT: The brake pedal must be attached to the power booster rod and undisturbed during the switch install. Do not press the brake pedal during the installation of the switch. 2. Push the stop lamp switch (3) into the retainer (2) until the switch plunger is fully depressed into the switch barrel. IMPORTANT: Approximately 2-3 lb of force is required to depress the switch plunger flush with the switch barrel. Too much force could flex the brake pedal bracket and result in the stop lamp switch not being properly adjusted. 3. Rotate the stop lamp switch (3) clockwise until the travel stop has been reached. 4. With a feeler gage check to ensure the minimum plunger extension is not less than 0.0 mm (0.0 in), and not greater than 2.0 mm (0.78 in) between the stop lamp switch barrel (3) and the brake pedal (4). 5. Connect the electrical connectors to the stop lamp switch. 6. Install the lower I/P trim insulator to the brake pedal bracket. 7. Install the lower I/P trim insulator screw. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 694 Tighten Tighten the screw to 2.3 N.m (20 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 698 Combination Switch: Service and Repair MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Lighting and Horns/Service Precautions/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). 4. Install the steering column trim covers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 699 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 704 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 705 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 708 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 709 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 710 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 711 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 712 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 715 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 716 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 717 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 721 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the fog lamp switch using a small flat-bladed tool. 5. Remove the fog lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the fog lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 728 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 729 Turn Signal Multifunction Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 732 4. Install the steering column trim covers. 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 733 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Upper Bearing Thrust Washer TURN SIGNAL CANCEL CAM AND UPPER BEARING THRUST WASHER TOOLS REQUIRED - J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/SIR Caution 2. Remove the SIR coil. 3. Remove and discard the bearing retainer using J 23653-SIR and J 42137. 4. Remove the shaft lock (1). 5. Remove the turn signal cancel cam (2). 6. Remove the upper bearing spring (3). 7. Remove the upper bearing inner race (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 734 1. Install the upper bearing inner race (4). 2. Install the upper bearing spring (3). 3. Install the turn signal cancel cam (2). 4. Lubricate the turn signal cancel cam (2) with GM P/N 12377900 (Canadian P/N 10953529). 5. Install the shaft lock (1). 6. Install the bearing retainer using J 23653-SIR and J 42137. 7. Install the SIR coil. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 740 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch Clutch Pedal Position (CPP) Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 741 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Remove the electrical connector from the clutch pedal position switch. 2. Remove the clutch pedal position switch from the brake and accelerator and clutch pedal with the bracket. Installation Procedure 1. Install the clutch pedal position switch to the brake and accelerator and clutch pedal with the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 742 2. Install the electrical connector to the clutch pedal position switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 746 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 747 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 748 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 752 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 753 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 754 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 757 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 758 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 762 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 763 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 764 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 768 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 769 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 770 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel tank pressure (FTP) sensor connector. 3. Remove the FTP sensor from the fuel sender. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 771 1. Install the FTP sensor to the fuel sender. 2. Connect the FTP sensor connector. 3. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 775 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 776 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the air cleaner duct from the air cleaner resonator. 2. Disconnect the IAT sensor harness connector. 3. While twisting the IAT sensor (4), pull the sensor from the air cleaner resonator (1). INSTALLATION PROCEDURE 1. Press the IAT sensor (4) into the air cleaner resonator (1). 2. Connect the IAT sensor harness connector. 3. Connect the air cleaner duct to the air cleaner resonator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 780 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 781 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 782 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 786 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 787 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the accelerator cable bracket. 3. Disconnect the manifold absolute pressure (MAP) sensor harness connector. 4. Remove the MAP sensor (2) from the intake manifold. 5. Inspect the seal for damage. IMPORTANT: If the MAP sensor seal is damaged, the MAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the MAP sensor (2) into the intake manifold. IMPORTANT: Use the new MAP sensor seal provided with the new MAP sensor. 2. Connect the MAP sensor harness connector. 3. Install the accelerator cable bracket. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 791 Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 792 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter Oxygen Sensor: Service and Repair Pre Catalytic Converter REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 795 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 796 Oxygen Sensor: Service and Repair Post Catalytic Converter REMOVAL PROCEDURE NOTE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. - Take care when handling the rear heated oxygen sensor (HO2S 2). The in-line connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn OFF the ignition. 2. Disconnect the HO2S 2 connector, in the Engine Compartment. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Carefully remove the HO2S 2. NOTE: The use of excessive force may damage the threads in the exhaust manifold/pipe. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. Coat the threads only of the HO2S 2 with anti-seize compound, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 797 2. Install the HO2S 2. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the HO2S 2 to 41 N.m (30 lb ft). 3. Lower the vehicle. 4. Reconnect the HO2S 2 connector, in the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 801 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 802 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 806 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 807 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 815 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 816 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 821 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 822 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 823 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 826 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 827 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 831 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 832 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 833 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: Customer Interest Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: All Technical Service Bulletins Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel Discriminating Sensor And Steering Wheel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 850 Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 851 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 852 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 853 Inflatable Restraint Side Impact Sensor - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 854 Inflatable Restraint Side Impact Sensor - Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 855 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 856 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on some vehicles to supplement SIR system performance. The EFS is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the EFS to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. INFLATABLE RESTRAINT SIDE IMPACT SENSORS (SIS) The side impact sensors (SIS) contain a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant side inflator module deployment. Each SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the side air bags. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the pushpin retainers from the hood close out panel. 3. Remove the hood close out panel from the vehicle. 4. Remove the connector position assurance (CPA) from the wiring harness connector. 5. Disconnect the wiring harness connector from the sensor (1). 6. Remove the mounting bolts (2) from the sensor (1). 7. Remove the sensor (1) from the hood latch support bracket (3). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 859 1. Install the sensor (1) to the hood latch support bracket (3). 2. Install the mounting bolts (2) to the sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the wiring harness connector to the sensor (1). 4. Install the CPA to the wiring harness connector. 5. Install the hood close out panel to the vehicle. 6. Install the pushpin retainers to the hood close out panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 860 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Sedan) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the center pillar upper trim. 3. Loosen the bolts (2) on the inflatable restraint side impact sensor. 4. Remove the inflatable restraint side impact sensor from the center pillar (1). 5. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 6. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 861 1. Connect the side impact sensor connector (4). 2. Install the CPA (3) to the side impact sensor connector (4). 3. Remove any dirt, grease, or other impurities from the mounting surface. 4. Install the side impact sensor to the center pillar (1). 5. Align the locating pin on the sensor to the opening in the center pillar (1). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar upper trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 862 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Coupe) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 or to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the door trim panel. 3. Remove enough of the water deflector to access the side impact sensor (1). 4. Loosen the bolts (2) on the inflatable restraint side impact sensor (1). 5. Remove the inflatable restraint side impact sensor (1) from the door (4). 6. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 7. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 863 2. Connect the side impact sensor connector (4). 3. Install the CPA (3) to the side impact sensor connector (4). 4. Install the side impact sensor (1) to the door (4). 5. Align the locating pin on the sensor (1) to the opening in the door (4). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the water deflector to the door. 7. Install the door trim panel. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 867 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 878 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 887 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 888 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 892 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 893 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 897 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 898 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 906 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 907 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 908 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 913 Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views Power Window Switch: Connector Views Master Window Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 916 Master Window Switch C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 917 Master Window Switch C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 918 Master Window Switch - (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 919 Window Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 920 Window Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 921 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to remove the power window switch bezel (1) from the console. 2. Remove the electrical connection from the power window switch (2). 3. With a flat-bladed tool release the power window switch (2) tabs, and remove the switch from the power window bezel (1) retainers. INSTALLATION PROCEDURE 1. Install the power window switch (2) into the power window switch bezel (1) until fully seated. 2. Connect the electrical connector to the power window switch (2). 3. Install the power window switch bezel (1) to the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 926 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 927 7. Ensure that the windshield wiper switch (2) functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 931 Windshield Wiper Switch Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 932 Wiper Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 933 7. Ensure that the windshield wiper switch (2) functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 939 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 940 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 941 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 942 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 943 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 944 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 945 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 948 Alignment: Specifications Wheel Alignment Specifications WHEEL ALIGNMENT SPECIFICATIONS FRONT SUSPENSION Camber ................................................................................................................................................ ......................................................... -0.20° ± 0.70° Camber Cross..................................................... ............................................................................................................................................. 0.00° ± 0.50° Caster ........................................................................................................................................ ..................................................................... 4.10° ± 0.75° Caster Cross Tolerance ........................... ....................................................................................................................................................... 0.00° ± 0.50° Total Toe ....................................................................................................................... .................................................................................0.10° ± 0.20° Steering Wheel Angle ................... .............................................................................................................................................................. ... 0.00° ± 3.50° REAR SUSPENSION Camber ................................................................................................................................................ ............................................................0.25° ± 0.25° Total Toe ........................................................... .......................................................................................................................................... +0.20° ± 0.20° Thrust Angle ............................................................................................................................... ................................................................... 0.00° ± 0.20° Caster (Nominal -- No means of adjustment provided) Camber Cross Tolerance (Nominal -- No means of adjustment provided) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 949 Alignment: Description and Operation CASTER DESCRIPTION Caster Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. CAMBER DESCRIPTION Camber Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. TOE DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 950 Toe Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. THRUST ANGLES DESCRIPTION The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. LEAD/PULL DESCRIPTION Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: - Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. TORQUE STEER DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 951 A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: - A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. - A large difference in the right and left front tire pressure - Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. MEMORY STEER DESCRIPTION Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. WANDER DESCRIPTION Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. SCRUB RADIUS DESCRIPTION Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection TRIM HEIGHT INSPECTION PROCEDURE TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. Refer to Label - Vehicle Certification. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within ± 10 mm (+/-3/8 in) to be considered correct. Z HEIGHT MEASUREMENT The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from bottom surface of the cradle (in line with the ball joint) to the bottom of the lower ball joint in order to obtain the Z height measurement. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications. D HEIGHT MEASUREMENT The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 954 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 in). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications. 10. If these measurements are out of specifications, inspect for the following conditions: - Improper weight distribution - Collision damage - Worn or damaged suspension components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 955 Alignment: Service and Repair Measuring Wheel Alignment MEASURING WHEEL ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: - Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. IMPORTANT:When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. FRONT CASTER ADJUSTMENT The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. FRONT CAMBER ADJUSTMENT 1. Loosen both strut to knuckle nuts just enough to allow for movement. 2. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 2.1. Disconnect the strut from the knuckle. 2.2. File the lower hole until the outer flange slot matches the inner flange slot. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 956 2.3. Connect the strut to the knuckle. 3. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications. NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Tighten the strut to knuckle nuts to 180 Nm (133 lb ft). FRONT TOE ADJUSTMENT 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (5). 3. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications. 4. Install the tie rod jam nut (5). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 345-414 kPa (50-60 psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 963 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 964 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Steps 1 - 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 965 Step 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 966 Steps 4 - 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 967 Steps 8 - 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 968 Steps 10 - 12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 969 Steps 13 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 970 Steps 15 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 971 Steps 19 - 21 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the outlet splash shield from the air cleaner. 2. Remove the left headlamp assembly. 3. Remove the upper push-in retainer (1) from the front air cleaner intake duct. 4. Remove the left front tire and wheel. 5. Remove the left front wheel house panel. 6. Remove the lower push-in retainer (4) from the front air cleaner intake duct. 7. Remove the front air cleaner intake duct (3) through the headlamp assembly opening. 8. Remove the resonator rear push-in retainer and the upper attaching bolt (5). 9. Remove the resonator assembly through the wheel house opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 979 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push-in retainer and the upper attaching bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (61 lb in). 3. Install the front air cleaner intake duct (3) through the headlamp assembly opening. 4. Install the lower push-in retainer (4) to the front air cleaner intake duct. 5. Install the left front wheel house panel. 6. Install the left front tire and wheel. 7. Lower the vehicle. 8. Install the upper push-in retainer (1) to the front air cleaner intake duct. 9. Install the headlamp assembly. 10. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 988 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 994 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 995 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the upper air cleaner cover screws to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1002 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1003 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 1012 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 1013 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition > Page 1019 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition > Page 1020 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1021 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 20.0 Nm (15.0 lb. ft.) Spark Plug Gap ................................................ ....................................................................................................................................... 1.06 mm (0.042 in.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1022 Spark Plug: Application and ID Spark Plug Type ........................................................................................................................................................ GM P/N 12569190 or AC P/N 41-981 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1023 Spark Plug: Testing and Inspection SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug. SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1024 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1025 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1026 Spark Plug: Service and Repair REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil housing. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. Refer to Spark Plug Inspection. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. GAP Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. IMPORTANT: DO NOT coat the spark plugs with anti seize compound. Over torquing could occur and damage to the cylinder head threads may result. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 1027 Tighten Tighten the spark plugs to 20 N.m (15 lb in). 3. Install the ignition coil housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Minimum ........................................................................................................ ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test Tools Required J 35667-A Cylinder Head Leakdown Tester or equivalent Important: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High leakage may indicate one or more of the following: ^ Worn or burnt valves ^ Broken valve springs ^ Stuck valve lifters ^ Incorrect valve lash/adjustment ^ Damaged piston ^ Worn piston rings ^ Worn or scored cylinder bore ^ Damaged cylinder head gasket ^ Cracked or damaged cylinder head ^ Cracked or damaged engine block Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the battery ground negative cable. 2. Remove the spark plugs. 3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke. 4. Install the J 35667-A or equivalent Important: It may be necessary to hold the crankshaft balancer bolt to prevent the engine from rotating. 5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. 6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: ^ Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. ^ Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. ^ Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. ^ Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 7. Perform the leakage test on the remaining cylinders and record the values. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test > Page 1033 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test Perform the following steps in order to conduct a compression test for the L61. 1. Conduct the following steps in order to check cylinder compression. 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1041 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1042 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1043 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Drive Belt Routing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Drive Belt Routing > Page 1046 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1047 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1050 is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1051 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1052 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1053 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1054 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1055 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1056 Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1057 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1058 Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1059 Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1060 Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1061 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front fender liner. 3. Rotate the drive belt tensioner counter-clockwise to release the spring tension. 4. Remove the drive belt. Installation Procedure 1. Rotate the drive belt tensioner counter-clockwise to release the spring tension. 2. Install the drive belt. 3. Install the front fender liner. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the outlet splash shield from the air cleaner. 2. Remove the left headlamp assembly. 3. Remove the upper push-in retainer (1) from the front air cleaner intake duct. 4. Remove the left front tire and wheel. 5. Remove the left front wheel house panel. 6. Remove the lower push-in retainer (4) from the front air cleaner intake duct. 7. Remove the front air cleaner intake duct (3) through the headlamp assembly opening. 8. Remove the resonator rear push-in retainer and the upper attaching bolt (5). 9. Remove the resonator assembly through the wheel house opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1067 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push-in retainer and the upper attaching bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (61 lb in). 3. Install the front air cleaner intake duct (3) through the headlamp assembly opening. 4. Install the lower push-in retainer (4) to the front air cleaner intake duct. 5. Install the left front wheel house panel. 6. Install the left front tire and wheel. 7. Lower the vehicle. 8. Install the upper push-in retainer (1) to the front air cleaner intake duct. 9. Install the headlamp assembly. 10. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1076 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1082 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1083 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the upper air cleaner cover screws to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations This vehicle does not have a factory installed cabin filter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement ^ Tools Required J 6125-1B Slide Hammer Adapter - J 23129 Universal Seal Remover Removal Procedure 1. Remove transaxle oil pan. 2. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 3. Check the oil filter seal for damage or wear. 4. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of petroleum jelly. 2. Install a new filter into the case. 3. Install transaxle oil pan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1096 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1097 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation Fuel Pump Pickup Filter: Customer Interest Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 1106 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 1107 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 1108 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System No Start/Low Power/Hesitation Fuel Pump Pickup Filter: All Technical Service Bulletins Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System No Start/Low Power/Hesitation > Page 1114 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System No Start/Low Power/Hesitation > Page 1115 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System No Start/Low Power/Hesitation > Page 1116 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1121 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 17 Nm (13 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1122 Oil Filter: Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1123 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1124 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. DO NOT use an open end wrench on the hex on top of the oil filter cap. 5. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1125 6. Remove the oil filter cap with filter. 7. Remove the filter from the cap. Installation Procedure 1. Install the filter to the cap. 2. Install the oil filter cap with filter. 3. DO NOT use an open end wrench on the hex on top of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1126 Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. 4. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the engine with oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation 1. Recover and recharge the A/C system. IMPORTANT: The in-line filter, AC Delco P/N 15-1760 must be installed to the A/C evaporator tube (liquid line) between the condenser and the evaporator. The installation of this in-line filter eliminates the need for flushing. 2. Remove the evaporator tube. 3. Remove and discard the existing orifice tube. IMPORTANT: The liquid filter, AC Delco P/N 15-1760 will have an orifice contained in it. 4. Wipe the A/C line with a clean cloth before cutting. 5. Make two marks 38 mm (1.5 in) apart on the liquid line. 6. Using the line cutter, cut the liquid line at the marked position and remove any burrs. IMPORTANT: Do not allow metal burrs from cutting the liquid line from dropping into the line and causing contamination. 7. Remove the nuts, the ferrules and the O-rings from the in-line filter. 8. Push the nuts and ferrules over each of the liquid line halves. IMPORTANT: Do not install the O-rings at this step. 9. Install the ferrules with the small end toward the nut. 10. Install the liquid line into the in-line filter making sure to bottom it out. 11. While holding liquid line bottomed-out in filter, tighten the nuts securely. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Disassemble the filter from the liquid line. 13. Lubricate the O-rings with clean 525 viscosity refrigerant oil and install them onto the liquid line. 14. Install the liquid line into the filter bottoming it out. 15. While holding liquid line bottomed-out in filter, tighten the nuts securely. Tighten Tighten the nuts to 15 N.m (11 lb ft). 16. Install the evaporator tube. 17. Evacuate, charge and leak test the system. 18. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 1131 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Loosen the A/C refrigerant filter nuts. IMPORTANT: The nuts and the ferrules will remain on the line. Do not try to remove. 3. Remove the A/C refrigerant filter. INSTALLATION PROCEDURE 1. Lubricate the O-rings with clean 525 viscosity refrigerant oil and install them onto the evaporator tube. 2. Install the A/C refrigerant filter with the arrow pointing toward the evaporator. 3. Ensure that the liquid line is bottomed out in the filter. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the filter nuts to 15 N.m (11 lb ft). 4. Evacuate and recharge the A/C system. 5. Leak test the fittings of the component. Using the J 39400-A 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Surge Tank Hose/Pipe Replacement Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement Surge Tank Hose/Pipe Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the surge tank pipe clamp (6) from the surge tank outlet hose (5). 3. Remove the surge tank pipe (7) from the surge tank outlet hose (5). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (9) from the surge tank pipe (7). 5. Remove the outlet hose (10) from the surge tank pipe (7). Installation Procedure 1. Install the outlet hose (10) to the surge tank pipe (7) 2. Use the J 38185 in order to reposition the surge tank pipe clamp (9) to the surge tank pipe (7). 3. Install the surge tank pipe (7) to the surge tank outlet hose (5). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (6). 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Surge Tank Hose/Pipe Replacement > Page 1137 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Outlet Surge Tank Hose/Pipe Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the surge tank outlet hose clamp (4) from the surge tank outlet hose (5). 3. Remove the surge tank outlet hose (5) from the surge tank. 4. Use the J 38185 in order to reposition the surge tank pipe clamp (6) from the surge tank pipe (7). 5. Remove the surge tank outlet hose (5) from the surge tank pipe (7). Installation Procedure 1. Install the surge tank outlet hose (5) to the surge tank pipe (7). 2. Use the J 38185 in order to reposition the surge tank pipe clamp (6) to the surge tank pipe (7). 3. Install the surge tank outlet hose (5) to the surge tank. 4. Use the J 38185 in order to reposition the surge tank outlet hose clamp (4) to the surge tank outlet hose (5). 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the inlet heater hose (1) from the inlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the inlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the inlet heater hose (2) to the inlet port of the heater core. 2. Lower the vehicle. 3. Connect the inlet heater hose to the inlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) > Page 1142 Heater Hose: Service and Repair Heater Hose Replacement - Outlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the outlet heater hose (2) from the outlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the outlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the outlet heater hose (1) to the outlet port of the heater core. 2. Lower the vehicle. 3. Connect the outlet heater hose to the outlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Hose/Line HVAC: Customer Interest A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 1151 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 1152 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Hose/Line HVAC: All Technical Service Bulletins A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 1158 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 1159 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement (L61) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the compressor hose assembly to the compressor bolt. 4. Remove the compressor hose assembly from the compressor. 5. Remove and discard the sealing washers. 6. Lower the vehicle. 7. Remove the hood close out filler panel. 8. Reposition the cruise control module out of the way, if equipped. 9. Remove the two nuts holding the bracket for the PCM Module. Position the bracket and module out of the way. 10. Disconnect the refrigerant pressure sensor electrical connector. 11. Remove the nut holding the compressor hose assembly fitting to the condenser. 12. Remove the compressor hose assembly from the condenser. 13. Remove and discard the O-ring seal. 14. Remove the fitting nut for the compressor hose assembly to accumulator. 15. Remove the compressor hose assembly from the accumulator (1). 16. Remove and discard the O-ring seals. 17. Remove the compressor hose assembly (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1162 1. Install a new O-ring seal to the accumulator end of the compressor hose assembly. 2. Install the compressor hose assembly and the fitting nut to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fitting nut to 35 N.m (26 lb ft). 3. Install a new O-ring seal to the condenser end of the compressor hose assembly. 4. Install the compressor hose assembly to the condenser. 5. Install the fitting nut for the compressor hose assembly to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 6. Install new sealing washers to the compressor ports. 7. Install the compressor hose assembly to the compressor. 8. Install the nut holding the compressor hose assembly to the compressor. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Lower the vehicle. 10. Connect the refrigerant pressure sensor electrical connector. 11. Position the bracket holding the PCM Module on to the shock tower. 12. Install the bracket nuts holding the PCM Module on to the shock tower. Tighten Tighten the nuts to 10 N.m (89 lb in). 13. Reposition the cruise control module. 14. Install the hood close out filler panel. 15. Evacuate and recharge the A/C system. 16. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1163 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 38185Hose Clamp Pliers REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the hood close out filler panel. 3. Use the J 38185 in order to reposition the hose clamps. Remove the coolant surge tank hoses from the surge tank. 4. Remove the nut connecting the evaporator tube to the condenser. 5. Discard the O-ring seal. 6. Remove the tube from the retaining clip (6) located on the body side rail 7. Remove the accumulator tube. 8. Raise the vehicle.Refer to Vehicle Lifting. 9. Remove the evaporator tube from the evaporator. 10. Discard the O-ring seals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1164 11. Lower the vehicle. 12. Remove the evaporator tube (4). INSTALLATION PROCEDURE 1. Install the evaporator tube (4). 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Install the evaporator tube to the evaporator. Use new O-ring seals. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fitting to 24 N.m (18 lb ft). 4. Lower the vehicle. 5. Install the tube to the retraining clip (6) located on the body side rail (2.4L only). 6. Install the evaporator tube to the condenser (3). Use the new O-ring seals. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Install the accumulator tube. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1165 8. Install the coolant surge tank hoses to the surge tank. Use the J 38185 in order to reposition the hose clamps. 9. Install the hood close out filler panel. 10. Evacuate and charge the A/C system. 11. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1166 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Reposition the cruise control module out of the way, if equipped. 3. Remove the 2 nuts holding the bracket for the PCM Module. Position the bracket and module out of the way. 4. Remove the accumulator tube fitting nut from the accumulator. Use a back-up wrench on the evaporator core fitting. 5. Remove the accumulator tube fitting nut from the evaporator core. 6. Remove the accumulator tube. 7. Remove and discard the O-rings. INSTALLATION PROCEDURE 1. Install new O-rings on both ends of the accumulator tube. 2. Install the accumulator tube to the accumulator and the evaporator core. 3. Install the accumulator tube fitting nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 35 N.m (26 lb ft). 4. Reposition the cruise control module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 1167 5. Position the bracket holding the PCM module on to the shock tower. 6. Install the bracket nuts holding the PCM module on to the shock tower. Tighten Tighten the nuts to 10 N.m (89 lb in). 7. Evacuate and recharge the A/C system. 8. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Locations Rack And Pinion System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe Power Steering Line/Hose: Service and Repair Power Steering - Pressure Pipe POWER STEERING PRESSURE PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the power steering pressure hose (3) from the power steering pressure pipe (4). 2. Remove the bolt (2) from the power steering pressure pipe bracket (3). 3. Remove the power steering pressure pipe (4) from the power steering pump (1). 4. Remove the power steering pressure pipe (4) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 1173 1. Install the power steering pressure pipe (4) to the vehicle. 2. Install the power steering pressure pipe (4) to the power steering pump (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the bolt (2) to the power steering pressure pipe bracket (3). Tighten Tighten the bolt to 26 N.m (19 lb ft). 4. Install the power steering pressure hose (3) to the power steering pressure pipe (4). Tighten Tighten the fitting to 27 N.m (20 lb ft). 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 1174 Power Steering Line/Hose: Service and Repair Power Steering - Pressure Hose POWER STEERING PRESSURE HOSE REPLACEMENT (WITH RPO CODE 2.2L (L61)) REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the front exhaust pipe, automatic transmission only. 3. Remove the power steering pressure hose (1) from the power steering gear (3). 4. Lower the vehicle. 5. Remove the upper air cleaner assembly. 6. Remove the power steering pressure hose (3) from the power steering pump pipe (4). 7. Remove the power steering pressure hose (3) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 1175 1. Install the power steering pressure hose (3) to the vehicle. NOTE: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Installing Hoses Without Twists or Bends Notice 2. Install the power steering pressure hose (3) to the power steering pump pipe (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the upper air cleaner assembly. 4. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 5. Install the front exhaust pipe, if removed. 6. Install the power steering pressure hose (1) to the power steering gear (3). Tighten Tighten the fitting to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 1176 Power Steering Line/Hose: Service and Repair Power Steering - Return Hose POWER STEERING RETURN HOSE REPLACEMENT (WITH RPO CODE 2.2L (L61)) REMOVAL PROCEDURE 1. Remove the upper air cleaner assembly. 2. Remove the clamp (5) and the power steering return hose (2) from the power steering pump (1). 3. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 4. Remove the front exhaust pipe, automatic transmission only. 5. Remove the power steering return hose (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 1177 1. Install the power steering return hose (2) to the vehicle. NOTE: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Installing Hoses Without Twists or Bends Notice 2. Install the power steering return hose (2) to the power steering gear (3). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the front exhaust pipe, if removed. 4. Lower the vehicle. 5. Install the power steering return hose (2) and the clamp (5) to the power steering pump (1). 6. Install the upper air cleaner assembly. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the inlet hose clamp (3) from the water outlet. 3. Remove the inlet radiator hose (2) from the water outlet. 4. Use the J 38185 in order to reposition the inlet hose clamp (1) to the radiator. 5. Remove the inlet radiator hose (2) from the radiator. Installation Procedure 1. Install the inlet radiator hose (2) to the radiator. 2. Use the J 38185 in order to reposition the inlet radiator hose clamp (1) to the radiator. 3. Install the inlet radiator hose (2) to the water outlet. 4. Use the J38185 in order to reposition the inlet radiator hose clamp (3) to the water outlet. 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 1182 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the outlet hose clamp (8) from the cylinder head. 3. Remove the outlet hose from the cylinder head (10). 4. Raise and suitably support the vehicle. 5. Use the J 38185 in order to reposition the surge tank pipe clamp (9). 6. Remove the outlet hose (10) from the surge tank pipe (7). 7. Use the J 38185 in order to reposition the outlet hose clamp (11) from the radiator. 8. Remove the outlet hose (10) from the radiator. Installation Procedure 1. Install the outlet hose (10) to the radiator. 2. Use the J 38185 in order to reposition the outlet hose clamp (11) to the radiator. 3. Install the outlet hose (10) to the surge tank pipe (7). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (9). 5. Lower the vehicle. 6. Install the outlet hose to the cylinder head (10). 7. Use the J 38185 in order to position the outlet hose clamp (8) to the cylinder head. 8. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1188 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1196 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1197 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1198 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1199 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .................................................. 8.2 liters (8.6 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1202 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1207 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1208 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1209 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 6.5L (6.9 Qt) Overhaul ........................... .............................................................................................................................................................. ................... 9.0L (9.5 Qt) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1212 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1213 Fluid - A/T: Service and Repair AUTOMATIC TRANSMISSION FLUID It is not necessary to check the transaxle fluid level. A transaxle fluid leak is the only reason for fluid loss. If a leak occurs have it repaired as soon as possible. You may also check your fluid level by following the Transmission Fluid Level and Condition Check procedure. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics Change both the fluid and filter every 50,000 miles (83 000 km) if the vehicle is mainly driven under one or more of these conditions: * In heavy city traffic where the outside temperature regularly reaches 90°F (32°C) or higher. * In hilly or mountainous terrain. * When doing frequent trailer towing. * Uses such as found in taxi, police or delivery service. If you do not use your vehicle under any of these conditions, the fluid and filter do not require changing. Notice: Use of automatic transaxle fluid labeled other than DEXRON-III may damage your vehicle, and the damages may not be covered by your warranty. Always use DEXRON-III labeled automatic transaxle fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................................. 1.7L (1.8 Qt) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1218 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................................. Dexron III Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1219 Fluid - M/T: Testing and Inspection Transmission Fluid Checking Procedure Important: Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. 1. Raise and support the vehicle. 2. Remove the level check plug. 3. Verify that the fluid is up to the opening. 4. Perform the following procedure if no fluid is visible: 4.1. Lower the vehicle. 4.2. Add GM Dexron III Transmission Fluid, or equivalent, to the level check opening until the level check opening begins to leak fluid. 4.3. Raise and suitably support the vehicle. 5. Install the fluid level check plug. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1220 Fluid - M/T: Service and Repair Transmission Fluid Checking Procedure Important: Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. 1. Raise and support the vehicle. 2. Remove the level check plug. 3. Verify that the fluid is up to the opening. 4. Perform the following procedure if no fluid is visible: 4.1. Lower the vehicle. 4.2. Add GM Dexron III Transmission Fluid, or equivalent, to the level check opening until the level check opening begins to leak fluid. 4.3. Raise and suitably support the vehicle. 5. Install the fluid level check plug. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1225 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1226 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.8L (5.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1229 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1230 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. DO NOT use an open end wrench on the hex on top of the oil filter cap. 5. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1231 6. Remove the oil filter cap with filter. 7. Remove the filter from the cap. Installation Procedure 1. Install the filter to the cap. 2. Install the oil filter cap with filter. 3. DO NOT use an open end wrench on the hex on top of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1232 Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. 4. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the engine with oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering System ....................................................................................................................... .................................................. 0.70 liters (1.5 pints) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1237 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1242 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1243 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant R134a ........................................................................................................................................................... 0.68 kg (1.5 lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1246 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1247 Refrigerant: Service Precautions 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. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a 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. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1248 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector 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. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a 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. NOTE: - 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. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - 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. - 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 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (L61) for the correct amount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY ACCUMULATOR REPLACEMENT ..................................................................................................................................................... 45 ml (1.5 oz) NOTE: Add PAG oil equal to the amount of oil drained from the old accumulator plus the specified additional amount. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 75 ml (2.5 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. The Delphi CVC6 service compressor is precharged with 148.0 ml (5 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. EVAPORATOR REPLACEMENT ......................................................................................................................................................... 30 ml (1.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 147 ml (5.0 oz) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1255 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1256 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (L61). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure ^ Items Required ^ A scan tool ^ J 29532 pressure bleeder with the proper master cylinder adapter ^ Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container ^ A hoist ^ An unbreakable plastic bleeder bottle equipped with a hose to recover fluid at the wheels ^ An assistant, if needed ^ The suitable safety attire, including safety glasses Automated Bleed Procedure Perform the automated ABS bleed procedure whenever one of the following conditions occurs: ^ Manual bleeding at the wheel cylinders does not achieve the desired pedal height or feel. ^ You replace the Brake Pressure Modulator Valve (BPMV). ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions applies, use standard bleed procedures. This procedure uses a scan tool in order to cycle the system solenoid valves and to run the pump motor in order to purge the air from the secondary circuits. These secondary circuits are normally closed, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or the calipers where the air can be purged out of the system. Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. 2. Connect a scan tool to the DLC connector and select Current and History DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks, repair as needed. Preliminary Setup 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Connect the J 29532 according to the manufacturer's instructions. 4. Turn the ignition switch to the ON position, engine OFF. 5. Connect a scan tool and establish communication with the ABS system. 6. Pressurize the bleeding tool to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the J 29532 at 35 psi, and all the bleeder screws in the closed position, select the Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and the front release valves for 1 minute. After the cycling has stopped the scan tool will enter a cool down mode and display a 3 minute timer. The auto bleed will not continue until this timer expires. You cannot override this timer. 3. The scan tool will request the technician to open one of the bleeder valves. The scan tool will then cycle this valve and the pump motor for 1 minute. 4. The scan tool repeats step 3 for the remaining bleeder valves. 5. With the J 29532 still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake pipes. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the J 29532 and then disconnect the J 29532 from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. 9. Repeat steps 1-8 until the pedal is acceptable. 10. Remove the scan tool from the DLC. 11. Lower the vehicle. 12. Inspect the brake fluid level in the master cylinder. 13. Road test the vehicle while verifying that the brake pedal remains high and firm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1262 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 392667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1263 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1264 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 44894-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1265 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve. then disconnect the J 29532, or equivalent, from the J 44894-A. 23. Remove the J 44894-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1266 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 115, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1271 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1272 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1273 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1274 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1275 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1276 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1277 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1278 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1279 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1280 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1281 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1282 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1283 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1284 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1285 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1286 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1287 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1288 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1289 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1290 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1291 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1292 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1293 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1294 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1295 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1296 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Block - I/P > Page 1304 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1307 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1308 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1309 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1310 Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1311 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1312 Fuse: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1313 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1314 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1315 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1316 Location View Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 1317 Location View Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Block - I/P > Page 1322 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1325 Fuse Block - I/P Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1326 Fuse Block - I/P Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1327 Fuse Block - I/P Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1328 Fuse Block - I/P Wire Entry Part 5 Fuse Block - Underhood Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1329 Fuse Block - Underhood Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1330 Fuse Block - Underhood Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1331 Fuse Block - Underhood Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1334 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1335 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1336 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1337 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1338 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1339 Fuse Block: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1340 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1341 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1342 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1343 Location View Application Table Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 1344 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1345 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Page 1346 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 1351 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 1354 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 1355 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 1356 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1357 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Page 1358 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned "ON", with the engine "OFF". This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns "OFF" after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns "OFF" after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is "ON". * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled "OFF" and then "ON". SERVICE VEHICLE SOON The instrument panel cluster (IPC) illuminates the service vehicle soon indicator during any of the following conditions: * The body control module (BCM) detects a PASSLOCK failure. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a malfunction in the passive trunk release system. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a failure in the traction control system. The BCM sends a class 2 message to the IPC requesting illumination. * The IPC detects a mismatch between its part number and the vehicle platform configuration sent by the BCM via a class 2 message. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1366 Malfunction Indicator Lamp: Service and Repair CHECK ENGINE OR SERVICE ENGINE SOON The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 1371 Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1387 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1401 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1406 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1407 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1408 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1409 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1410 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1411 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1412 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1413 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1414 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1415 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1416 Inflation Pressure Converrsion (Kilopascals To PSI) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1417 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1418 Tires: Description and Operation TREAD WEAR INDICATORS DESCRIPTION The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 72 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). TIRE INFLATION DESCRIPTION When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and tires are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures, or under-inflated tires, can cause the following conditions: - Vehicle handling concerns - Poor fuel economy - Shortened tire life - Tire overloading Inspect the tire pressure when the following conditions apply: - The vehicle has been sitting at least 3 hours. - The vehicle has not been driven for more than 1.6 km (1 mi). - The tires are cool. Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications on the tire label. Install the valve caps or the extensions on the valves. The caps or the extensions keep out dust and water. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1419 Inflation Pressure Converrsion (Kilopascals To PSI) The kilopascal kPa) is the metric term for pressure. The tire pressure may be printed in both kilopascal kPa) and psi. One psi equals 6.9 kPa. Tires with a higher than recommended pressure can cause the following conditions: - A hard ride - Tire bruising - Rapid tread wear at the center of the tire Tires with a lower than recommended pressure can cause the following conditions: - A tire squeal on turns - Hard steering - Rapid wear and uneven wear on the edge of the tread - Tire rim bruises and tire rim rupture - Tire cord breakage - High tire temperatures - Reduced vehicle handling - High fuel consumption - Soft riding Unequal pressure on the same axle can cause the following conditions: - Uneven braking - Steering lead - Reduced vehicle handling Refer to the Tire Placard for specific tire and wheel applications and tire pressures. ALL SEASONS TIRES DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 1420 Most GM vehicles are equipped with steel belted all-season radial tires as standard equipment. These tires qualify as snow tires, with a higher than average rating for snow traction than the non-all season radial tires previously used. Other performance areas, such as wet traction, rolling resistance, tread life, and air retention, are also improved. This is done by improvements in both tread design and tread compounds. These tires are identified by an M+ S molded in the tire side wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification number. The optional handling tires used on some vehicles now also have the MS marking after the tire size and the TPC specification number. P-METRIC SIZED TIRES DESCRIPTION Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement tires should be of the same tire performance criteria (TPC) specification number including the same size, the same load range, and the same construction as those originally installed on the vehicle. Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection Tires: Service and Repair Tire and Wheel Rotation and Inspection TIRE AND WHEEL INSPECTION AND ROTATION Tires should be rotated every 6,000 to 8,000 miles (10 000 km to 13 000 km). CAUTION: Rust or dirt on a wheel, or on the parts to which it is fastened, can make wheel nuts become loose after a time. The wheel could come off and cause an accident. When you change a wheel, remove any rust or dirt from places where the wheel attaches to the vehicle. In an emergency, you can use a cloth or a paper towel to do this; but be sure to use a scraper or wire brush later, if you need to, to get all the rust or dirt off. 1. Check the tires for abnormal wear or damage. 2. Ensure the spare tire is stored securely. Push, pull, and then try to rotate or turn the tire. If it moves, use the folding wrench to tighten the cable. 3. Rotate the tires to equalize the wear and obtain maximum tire life. 4. When rotating tires, always use the correct rotation pattern shown here. 5. Do not include the compact spare tire in tire rotation. 6. After the tires have been rotated, adjusted the front and rear inflation pressures as shown on the Certification/Tire label. Ensure that all wheel nuts are properly tightened. 7. Make certain that all wheel nuts are properly tightened. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 1423 Tires: Service and Repair Tire and Wheel - Removal and Installation TIRE AND WHEEL REMOVAL AND INSTALLATION TOOLS REQUIRED J 39544-KIT Complete Torque Socket Set CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. NOTE: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. IMPORTANT:Removing wheels can be difficult because of foreign material or a tight fit between the wheel and the hub / rotor. Slightly tap the tire side wall with a rubber mallet in order to remove the wheel. Failure to follow these instructions may result in damage to the wheel. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. REMOVAL PROCEDURE 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. INSTALLATION PROCEDURE CAUTION: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. NOTE: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 1424 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice IMPORTANT:Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten Tighten the nuts in a criss/cross pattern to 140 N.m (100 lb ft). 3. Remove the safety stands and lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 1425 Tires: Service and Repair Tire - Repair TIRE REPAIR Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 1426 Tires: Service and Repair Tire - Mounting and Dismounting TIRE MOUNTING AND DISMOUNTING NOTE: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Deflate the tire completely. NOTE: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 2. Use the tire changer in order to remove the tire from the wheel. IMPORTANT:Rim-clamp European-type tire changers are recommended. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. 4. Apply GM P/N 12345884 (Canadian P/N 5728223) or equivalent to the tire bead and the wheel rim. NOTE: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 5. Use the tire changer in order to install the tire to the wheel. 6. Inflate the tire to the proper air pressure. CAUTION: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa(40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1435 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1436 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1437 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1442 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1447 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1448 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1449 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheels: Customer Interest Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1454 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1455 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1456 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1457 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1463 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1464 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1465 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1470 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1475 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1476 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1481 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1482 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 1483 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 1488 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1493 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1494 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 1495 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheels: All Technical Service Bulletins Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1504 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1505 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1506 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1507 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1513 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1514 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 1515 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 1520 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1525 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 1526 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1531 Wheels: Description and Operation REPLACEMENT WHEELS DESCRIPTION Replace the wheel if any of the following conditions exist: - The wheel exhibits excessive runout. - The wheel is bent. - The wheel is cracked. - The wheel is severely rusted. - The wheel is severely corroded. - The wheel leaks air. IMPORTANT:Air leaks caused by porosity on aluminum wheels are repairable. CAUTION: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. NOTE: The use of non-GM original equipment wheels may cause: Damage to the wheel bearing, the wheel fasteners and the wheel Tire damage caused by the modified clearance to the adjacent vehicle components Adverse vehicle steering stability caused by the modified scrub radius Damage to the vehicle caused by the modified ground clearance Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: - The wheel has elongated bolt holes. - The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. STEEL WHEEL REPAIR DESCRIPTION NOTE: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation Wheels: Service and Repair Tire and Wheel - Removal and Installation TIRE AND WHEEL REMOVAL AND INSTALLATION TOOLS REQUIRED J 39544-KIT Complete Torque Socket Set CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. NOTE: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. IMPORTANT:Removing wheels can be difficult because of foreign material or a tight fit between the wheel and the hub / rotor. Slightly tap the tire side wall with a rubber mallet in order to remove the wheel. Failure to follow these instructions may result in damage to the wheel. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. REMOVAL PROCEDURE 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. INSTALLATION PROCEDURE CAUTION: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. NOTE: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 1534 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice IMPORTANT:Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten Tighten the nuts in a criss/cross pattern to 140 N.m (100 lb ft). 3. Remove the safety stands and lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 1535 Wheels: Service and Repair Aluminum Wheel - Porosity Repair ALUMINUM WHEEL POROSITY REPAIR 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel.. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. IMPORTANT:Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing Off-Vehicle in Vibration Diagnosis and Correction. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 1536 Wheels: Service and Repair Aluminum Wheel - Refinishing ALUMINUM WHEEL REFINISHING FINISH DAMAGE EVALUATION PROCEDURE 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. IMPORTANT:If the wheels are chrome-plated, do not re-plate or refinish the wheels. If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for the following conditions: - Corrosion - Scrapes - Gouges 2. Verify the damage is not deeper than what sanding can remove. 3. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 4. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. REFINISHING PROCEDURE 1. Remove the tire and wheel assembly from the vehicle. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: - Lubricants - Wax - Dirt 5. Use plastic media blasting in order to remove the paint from the wheel. IMPORTANT:Do not re-machine the wheel. Do not use chemicals in order to strip the paint from the wheel. 1. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. 2. Mask the wheel mounting surface and the wheel nut contact surface. IMPORTANT:The wheel mounting surface and the wheel nut contact surface must remain free of paint. 3. Follow the paint manufacturer's instructions for painting the wheel. 4. Unmask the wheel. 5. Install a new valve stem. 6. Install the tire to the wheel. IMPORTANT:Use new coated balance weights in order to balance the wheel. 7. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: - Corrosion - Overspray - Dirt 8. Install the tire and wheel assembly to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection WHEEL BEARINGS DIAGNOSIS TOOLS REQUIRED J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Hub/Axle Flange and Wheel Stud Runout Inspection in Vibration Diagnosis and Correction. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. IMPORTANT:If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 in), replace the wheel bearing/hub. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension WHEEL BEARING/HUB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the drive axle nut. 4. Remove the brake rotor 5. Remove the mounting bolts (1) from the hub and bearing assembly (3). 6. Remove the hub and bearing assembly (1) from the steering knuckle (2) and drive axle shaft. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1542 1. Install the hub and bearing assembly (1) into the steering knuckle (2) and drive axle shaft. 2. Install the hub bearing mounting bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 95 N.m (70 lb ft). 3. Install the drive axle shaft nut. Tighten Tighten the drive axle shaft nut to 200 N.m (148 lb ft). 4. Install the brake rotor. 5. Install the tire and wheel assemblies. 6. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 1543 Wheel Bearing: Service and Repair Rear Suspension WHEEL BEARING/HUB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake drum. NOTE: Do not hammer on brake drum as damage to the bearing could result. 4. Disconnect the rear ABS wheel speed sensor wire connector. 5. Remove the hub and bearing assembly bolts 6. Remove the hub and bearing assembly from the axle. INSTALLATION PROCEDURE 1. Install the hub and bearing assembly to the axle in the axle assembly. NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the hub and bearing assembly bolts. Tighten Tighten the hub and bearing to axle bolts to 60 N.m (44 lb ft). 3. Connect the rear ABS wheel speed sensor wire connector. 4. Install the brake drum. 5. Install the tire and wheel assemblies. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheel Cover: Customer Interest Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1552 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1553 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1554 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1555 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheel Cover: All Technical Service Bulletins Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1561 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1562 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1563 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 1564 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Axle Nut ...................................................................................................................................... .................................................. 200 N.m (148 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1577 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 1583 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1584 Wheel Fastener: Specifications WHEEL FASTENER TORQUE Tighten the nuts in a criss/cross pattern to 140 Nm (100 lb. ft.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1585 Wheel Nut Torque Sequence Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 1586 Wheel Fastener: Description and Operation METRIC WHEEL NUTS AND BOLTS DESCRIPTION Metric wheel/nuts and bolts are identified in the following way: - The wheel/nut has the word Metric stamped on the face. - The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. - M = Metric - 12 = Diameter in millimeters - 1.5 = Millimeters gap per thread Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension WHEEL STUD REPLACEMENT TOOLS REQUIRED J 43631 Ball Joint Separator REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the wheel stud (1) from the hub and bearing assembly (2) using the J 43631. 5. Discard the stud. INSTALLATION PROCEDURE 1. Install the replacement stud into the hub and bearing assembly (2). 2. Add enough washers in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the hub and bearing assembly. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1589 Wheel Fastener: Service and Repair Rear Suspension WHEEL STUD REPLACEMENT TOOLS REQUIRED J 43631 Ball Joint Separator REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. 2. Remove the tire and the wheel assembly. 3. Remove the brake drum. 4. Remove the wheel stud using the J 43631 NOTE: Do not hammer on brake drum as damage to the bearing could result. 5. Discard the wheel stud. INSTALLATION PROCEDURE 1. Install the new stud from the back side of the hub. 2. Install the four flat washers (3) on the hub. 3. Install the wheel nut with the flat side toward the washers. 4. Tighten the nut until the stud is properly seated in the hub flange. 5. Remove the nut and the washers. 6. Install the brake drum. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 1590 7. Install the tire and the wheel assembly. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 1594 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery. Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery. Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery. This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1599 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1600 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1601 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1602 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1603 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 1604 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Minimum ........................................................................................................ ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test Tools Required J 35667-A Cylinder Head Leakdown Tester or equivalent Important: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High leakage may indicate one or more of the following: ^ Worn or burnt valves ^ Broken valve springs ^ Stuck valve lifters ^ Incorrect valve lash/adjustment ^ Damaged piston ^ Worn piston rings ^ Worn or scored cylinder bore ^ Damaged cylinder head gasket ^ Cracked or damaged cylinder head ^ Cracked or damaged engine block Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the battery ground negative cable. 2. Remove the spark plugs. 3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke. 4. Install the J 35667-A or equivalent Important: It may be necessary to hold the crankshaft balancer bolt to prevent the engine from rotating. 5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. 6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: ^ Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. ^ Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. ^ Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. ^ Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 7. Perform the leakage test on the remaining cylinders and record the values. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test > Page 1612 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test Perform the following steps in order to conduct a compression test for the L61. 1. Conduct the following steps in order to check cylinder compression. 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt First Pass ............................................................................................................................................. .................................................. 85 Nm (63 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 30 degrees Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Bearing Cap Bolt ................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Intake Camshaft Rear Cap Bolt ....................... ......................................................................................................................................... 25 Nm (18 ft. lbs.) Cam Bearing I.D. .................................................................................................................................................. 27.000-27.021 mm (1.0630-1.0638 inch) Cam Journal O.D. .................................................................................................................................................. 26.935-26.960 mm (1.0604-1.0614 inch) Camshaft Bearing Clearance ..................................................................................................................................... 0.040-0.086 mm (0.0016-0.0034 inch) Camshaft Thrust Width-Cylinder Head ................................................................................................................. 20.868-20.920 mm (0.8215-0.8236 inch) Camshaft Thrust Width-Camshaft ......................................................................................................................... 21.000-21.052 mm (0.8268-0.8252 inch) Camshaft Endplay ..................................................................................................................................................... 0.040-0.144 mm (0.0016-0.0057 inch) Cam Timing, Intake ................................................................ ..................................................................................................................... 114-120° ATDC Cam Timing, Exhaust ................................................................................................................................... ......................................... 111.5-117.5° BTDC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement Camshaft: Service and Repair Intake Camshaft and Lifter Replacement Intake Camshaft and Lifter Replacement ^ Tools Required J 43655 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the upper timing chain guide. 3. Install the J 43655. 4. Remove both the intake and exhaust camshaft sprocket bolts and discard. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1622 5. Slide the camshaft sprockets forward. 6. Remove the power steering pump bolts and set pump aside. 7. Mark bearing caps to ensure they are installed in the original position. Important: Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft. 8. Remove the bearing caps. 9. Remove the intake camshaft. 10. Remove the camshaft roller followers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1623 11. Remove the hydraulic element lash adjusters. Installation Procedure 1. Lubricate the valve tips. 2. Install the hydraulic element lash adjusters. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1624 3. Install the camshaft roller followers. 4. Ensure that the alignment notches are aligned with the camshaft sprocket. 5. Install the intake camshaft. 6. Install the camshaft bearing caps. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. ^ Tighten the camshaft bearing cap bolts to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1625 8. Apply anaerobic sealer, 5 mm (0.197 inch) bead, GM P/N 1052942 (Canadian P/N 10953466) to the rear intake camshaft bearing cap. 9. Install the rear intake camshaft bearing cap bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 10. Install camshaft sprockets onto the camshafts. 11. Hand tighten NEW camshaft sprocket bolts. 12. Remove the J 43655. 13. Tighten the camshaft sprocket bolts. ^ Tighten the bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 14. Install the upper timing chain guide. ^ Tighten the upper timing chain guide to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1626 15. Install the power steering pump. ^ Tighten the power steering pump bolts to 25 Nm (19 ft. lbs.). 16. Install the camshaft cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1627 Camshaft: Service and Repair Exhaust Camshaft and Lifter Replacement Exhaust Camshaft and Lifter Replacement ^ Tools Required J 43655 Camshaft Sprocket Holding Tool Removal Procedure 1. Remove the camshaft cover. 2. Remove the upper timing chain guide. 3. Install the J43655. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1628 4. Remove both the intake and the exhaust camshaft sprocket bolts and discard. 5. Slide the camshaft sprockets forward. 6. Mark the bearing caps to ensure that the bearing caps are installed in the original position. Important: Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft. 7. Remove the bearing caps. 8. Remove the exhaust camshaft. 9. Remove the camshaft roller followers. 10. Remove the hydraulic element lash adjusters. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1629 Installation Procedure 1. Lubricate the valve tips. 2. Install the hydraulic element lash adjusters. 3. Install the camshaft roller followers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1630 4. Ensure that the alignment notches are aligned with the camshaft sprocket. 5. Install the exhaust camshaft. 6. Install the camshaft bearing caps. Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. ^ Tighten the camshaft bearing cap bolts to 10 Nm (89 inch lbs.). 8. Install camshaft sprockets onto the camshafts. 9. Hand tighten NEW camshaft sprocket bolts. 10. Remove the J43655. 11. Tighten the camshaft sprocket bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Intake Camshaft and Lifter Replacement > Page 1631 ^ Tighten the bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 12. Install the upper timing chain guide. ^ Tighten the upper timing chain guide to 10 Nm (89 inch lbs.). 13. Install the camshaft cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Lifter Guide .......................................................................................................................................... ................................................. 11 Nm (97 inch lbs.) Stationary Lash Adjuster Bore I.D. ....................................................................................................................... 12.013-12.037 mm (0.4730-0.4739 inch) Stationary Lash Adjuster O.D. .............................................................................................................................. 11.986-12.000 mm (0.0005-0.0020 inch) Stationary Lash Adjuster Clearance ....................................................................................................................... 0.013-0.051 mm (3.2210-3.2299 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 1635 Lifter / Lash Adjuster: Service and Repair "For information regarding this component please refer to camshaft service and repair" Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts ................................................................................................................................. .................................................... 25 Nm (19 ft. lbs.) Stationary Lash Adjuster Bore I.D. .................................................................................................................... 12.013-12.037 mm (0.4730-0.4739 inch) Stationary Lash Adjuster O.D. .............................................................................................................................. 11.986-12.000 mm (0.0005-0.0020 inch) Stationary Lash Adjuster Clearance ....................................................................................................................... 0.013-0.051 mm (3.2210-3.2299 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance Shaft Bearing Carrier Bore in Block I.D. ................................................................................................ 42.000-42.016 mm (1.6535-1.6542 inch) Balance Shaft Bearing Carrier O.D. ...................................................................................................................... 41.975-41.995 mm (1.6526-1.6534 inch) Balance Shaft Housing to Block Clearance ............................................................................................................... 0.005-0.041 mm (0.0002-0.0016 inch) Balance Shaft Bearing I.D. #1 ............................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 inch) Balance Shaft Bearing I.D. #2 ............................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 inch) Balance Shaft Journal O.D. #1 .............................................................................................................................. 20.000-20.020 mm (0.7874-0.7882 inch) Balance Shaft Journal O.D. #2 .............................................................................................................................. 36.723-36.743 mm (1.4458-1.4466 inch) Balance Shaft Bearing Clearance #1 .......................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 inch) Balance Shaft Bearing Clearance #2 .......................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 inch) Balance Shaft End Play ............................................................................................................................................. 0.100-0.300 mm (0.0020-0.0118 inch) Balance Shaft Chain Length .......................................................................................................................... 368.622-369.032 mm (14.5127-14.5288 inch) Balance of Shafts .......................................................................................... .......................................................................... 4.05 Kg/mm per shaft, +/-6 % Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Balance Shaft Bearing Carrier to Block Bolt ........................................................................................................................................ 10 Nm (89 inch lbs.) Balance Shaft Bearing Carrier Bore in Block I.D. ................................................................................................ 42.000-42.016 mm (1.6535-1.6542 inch) Balance Shaft Bearing Carrier O.D. ...................................................................................................................... 41.975-41.995 mm (1.6526-1.6534 inch) Balance Shaft Bearing I.D. #1 ............................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 inch) Balance Shaft Bearing I.D. #2 ............................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 inch) Balance Shaft Bearing Clearance #1 .......................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 inch) Balance Shaft Bearing Clearance #2 .......................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance Shaft Adjustable Chain Guide Bolt ......................................................................................................................................... 10 Nm (89 inch lbs.) Balance Shaft Fixed Chain Guide Bolt .................................................................................................................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Gear > Component Information > Specifications Balance Shaft Gear: Specifications Balance Shaft Sprocket Bolt ................................................................................................................ ..................................................... 50 Nm (37 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Rod Bearing Bore I.D. .......................................................................................................................................... 52.118-52.134 mm (2.0519-2.0525 inch) Rod Bearing Shell Thickness ...................................................................................................................................... 1.539-1.545 mm (0.0606-0.608 inch) Rod Bearing I.D., 90 degree ................................................................................................................................. 49.043-49.073 mm (1.9308-1.9320 inch) Rod Bearing I.D., 45 degree ................................................................................................................................. With-in +0.009/-0.004 of 90 degree spec. Rod Bearing to Crankpin Clearance .......................................................................................................................... 0.029-0.069 mm (0.0011-0.0027 inch) Rod Small End I.D. ............................................................................................ ...................................................................................... 20.007-20.021 mm Rod Side Clearance ................................................................................................................................................... 0.070-0.370 mm (0.0028-0.0146 inch) Rod Twist ............................................................................... .............................................................................................................................. 0.040 max. Rod Bend .................................................................................................................................................... .......................................................... 0.021 max. Rod Large End Micro ............................................. ............................................................................................................................................ 2.0 Ra max. Rod Small End Micro .................................................................................................................. ....................................................................... 0.3 Ra max. Piston Pin Endplay ....................................................................................................................................................... 0.19-1.16 mm (0.007 5-0.0461 inch) Connecting Rod Bolt First Pass ............................................................................................................................................. ................................................................. 18 ft.lbs. Final Pass ........................................................... ......................................................................................................................................................... 100° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Rod Bearing Bore I.D. .......................................................................................................................................... 52.118-52.134 mm (2.0519-2.0525 inch) Rod Bearing Shell Thickness ...................................................................................................................................... 1.539-1.545 mm (0.0606-0.608 inch) Rod Bearing I.D., 90 degree ................................................................................................................................. 49.043-49.073 mm (1.9308-1.9320 inch) Rod Bearing I.D., 45 degree ................................................................................................................................. With-in +0.009/-0.004 of 90 degree spec. Rod Bearing to Crankpin Clearance .......................................................................................................................... 0.029-0.069 mm (0.0011-0.0027 inch) Rod Small End I.D. ............................................................................................ ...................................................................................... 20.007-20.021 mm Rod Side Clearance ................................................................................................................................................... 0.070-0.370 mm (0.0028-0.0146 inch) Rod Twist ............................................................................... .............................................................................................................................. 0.040 max. Rod Bend .................................................................................................................................................... .......................................................... 0.021 max. Rod Large End Micro ............................................. ............................................................................................................................................ 2.0 Ra max. Rod Small End Micro .................................................................................................................. ....................................................................... 0.3 Ra max. Piston Pin Endplay ....................................................................................................................................................... 0.19-1.16 mm (0.007 5-0.0461 inch) Connecting Rod Bolt First Pass ............................................................................................................................................. ................................................................. 18 ft.lbs. Final Pass ........................................................... ......................................................................................................................................................... 100° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Bolt Tightening Sequence Install the NEW crankshaft bearing bolts in sequence finger tight. - Tighten the crankshaft bearing bolts in sequence. - Tighten the crankshaft bearing bolts to 20 Nm (15 ft. lbs.). - Tighten the crankshaft bearing bolts in sequence. - Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter. Lower Crankcase Perimeter Tightening Sequence -Tighten the lower crankcase to block peripheral bolts to 25 N-m (18 ft.lbs.) Main Journal O.D. ................................................................................................................................................. 55.994-56.008 mm (2.2045-2.2050 inch) Main Bearing Clearance ............................................................................................................................................ 0.031-0.067 mm (0.0012-0.0026 inch) Rod Pin O.D. ......................................................................................................................................................... 49.000-49 014 mm (1.9291-1.9297 inch) Rear Crankshaft Seal O.D. ............................................................................................................................................ 89.78-90.00 mm (3.535-3.543 inch) Crankshaft Endplay ................................................................................................................................................... 0.050-0.380 mm (0.0012-0.0150 inch) Balance of Crankshaft ............................................................ ........................................................................................................................... 10 g/cm max. Balance of Flywheel ............................................................................................................................ ............................................................. 10 g/cm max. Balance of Crankshaft Damper ....................... ............................................................................................................................................ 0.09 kg/mm max. Main Bearing Shell Thickness .................................................................................................................................. 4.030-4.037 mm (0.1587-0.1589 inch) Main Bearing I.D. ................................................................................................................................................. 56.035-56.065 mm (2.2061-2.2073 inch) Crankshaft Bearing - Lower Crankcase to Block First Pass ............................................................................................................................................. ................................................................. 15 ft.lbs. Final Pass ........................................................... ........................................................................................................................................................... 70° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Bearing Bolt Tightening Sequence Install the NEW crankshaft bearing bolts in sequence finger tight. - Tighten the crankshaft bearing bolts in sequence. - Tighten the crankshaft bearing bolts to 20 Nm (15 ft. lbs.). - Tighten the crankshaft bearing bolts in sequence. - Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter. Lower Crankcase Perimeter Tightening Sequence -Tighten the lower crankcase to block peripheral bolts to 25 N-m (18 ft.lbs.) Main Journal O.D. ................................................................................................................................................. 55.994-56.008 mm (2.2045-2.2050 inch) Main Bearing Clearance ............................................................................................................................................ 0.031-0.067 mm (0.0012-0.0026 inch) Rod Pin O.D. ......................................................................................................................................................... 49.000-49 014 mm (1.9291-1.9297 inch) Rear Crankshaft Seal O.D. ............................................................................................................................................ 89.78-90.00 mm (3.535-3.543 inch) Crankshaft Endplay ................................................................................................................................................... 0.050-0.380 mm (0.0012-0.0150 inch) Balance of Crankshaft ............................................................ ........................................................................................................................... 10 g/cm max. Balance of Flywheel ............................................................................................................................ ............................................................. 10 g/cm max. Balance of Crankshaft Damper ....................... ............................................................................................................................................ 0.09 kg/mm max. Main Bearing Shell Thickness .................................................................................................................................. 4.030-4.037 mm (0.1587-0.1589 inch) Main Bearing I.D. ................................................................................................................................................. 56.035-56.065 mm (2.2061-2.2073 inch) Crankshaft Bearing - Lower Crankcase to Block First Pass ............................................................................................................................................. ................................................................. 15 ft.lbs. Final Pass ........................................................... ........................................................................................................................................................... 70° Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure Technical Service Bulletin # 03-06-01-018D Date: 060405 Engine - Revised Cylinder Sleeve Replacement Procedure Bulletin No.: 03-06-01-018D Date: April 05, 2006 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2002-2005 Chevrolet Cavalier 2004-2006 Chevrolet Classic, Malibu 2005-2006 Chevrolet Cobalt, Cobalt SS 2006 Chevrolet HHR 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Sunfire 2002-2006 Pontiac Grand Am 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Soltice with Ecotec 2.0L, 2.2L or 2.4L 4-Cylinder Engine (VINs P, F, B - RPOs LSJ, L61, LE5) Supercede: This bulletin is being revised to provide updated cylinder sleeve replacement procedures. Please discard Corporate Bulletin Number 03-06-01-018C (Section 06 - Engine). This bulletin is being issued to update cylinder sleeve replacement in the Engine Mechanical sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. The new procedure for the 2.0L, 2.2L and 2.4L four cylinder engines has been developed to replace the cylinder bore sleeve when the engine is in or out of the vehicle. Tools Required EN45680-850 Cylinder Sleeve Removal and Installation Kit Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1668 For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1669 Disclaimer Procedures Removal Procedure Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. Remove the cylinder head. 2. Remove the oil pan. Refer to Oil Pan Replacement. 3. Remove the piston and connecting rod. Refer to Piston, Connecting Rod, and Bearing Removal. 4. Inspect the condition of the piston. Refer to Piston, Connecting Rod, and Bearings Cleaning and Inspection. 5. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 6. Install the EN 45680-852 cylinder bore sleeve puller (1) through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore liner or damage to the cylinder bore liner puller EN45680-852 will occur. 7. Align the shoe (1) of the EN 45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1670 8. Hold the threaded shaft of the EN 45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 9. Install the EN 456850-851 fixture (4) onto the threaded shaft of the EN 456850-852 cylinder bore sleeve puller and the engine block. 10. Install the bearing (3) and the nut (1). 11. Tighten the nut (1) to the bearing (3). 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 coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Use 4 old cylinder head bolts for the attaching bolts 12. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten Tighten the bolts to 15 N.m (11 lb-ft). 13. Rotate the nut clockwise in order to remove the cylinder bore liner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1671 Note: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. 14. Remove EN 45680-851 fixture, EN 45680-852 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block. 15. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Installation Procedure Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve onto the cylinder block. 2. Install EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve. 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 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. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1672 Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the EN 45680-851 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten Tighten the 4 attachment bolts to 15 N.m (11 lb-ft). 4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1673 5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2). 6. Align the pusher block (2) of EN 45680-853 cylinder bore sleeve installer into the groove of EN 45680-851 fixture (1). Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-851/cylinder bore liner installer EN 45680-853 assembly or damage to the cylinder bore liner will occur. 7. Using a ratchet, rotate the threaded shaft of EN 45680-85 fixture and EN 45680-853 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1674 8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block. 9. Using a torque wrench, tighten the threaded shaft of the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly to 102 Nm (75 lb-ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface. 10. Remove the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly (1) from the cylinder block (2). Cylinder Liner Trimming Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1675 Note: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. Note: Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings. 2. Place the EN 45680-863 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1676 3. Place additional EN 45680-863 metal shaving catch plugs into all remaining cylinder bore sleeves. NOTE: Installing the metal shaving catch plug EN 45680-863 deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure. Note: Installing the metal shaving catch plug EN 45680-863 above the recommended depth will cause damage to the metal shaving catch plug EN 45680-863. 4. Ensure that the EN 45680-863 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Important: Before using EN 45680-861 trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the EN 45680-862 set gage ring (1) should be positioned upward on a flat surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1677 Important: Ensure that the EN 45680-862 set gage ring surfaces are clean. 6. Carefully position EN 45680-861 trim tool assembly onto the EN 45680-862 set gage ring. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the EN 45680-861 trim tool assembly height until the blades are worn or damaged 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten Tighten the shaft collar screw to 19 N.m (14 lb-ft). 10. Place the EN 45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block. 11. Install the EN 45680-864 4 bolts into the cylinder head bolt holes in the block. Tighten Tighten the bolts to 20 N.m (15 lb-ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1678 Note: For proper tool operation a drill motor with a 1/2 inch chuck 1-1/8 hp. 7 amps, triple gear reduction and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur. 12. Fasten the drive adapter EN 45680-866 into the drill chuck. Note: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage. 13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-861 trim tool assembly Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place the EN 45680-866 drive adapter and the drill assembly vertically onto the EN 45680-861 drive adapter end of trim tool assembly . Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove the EN 45680-866 drive adapter (1) and the drill assembly from the EN 45680-861 trim tool assembly. 16. Turn OFF the compressed air valve. 17. Remove the EN 45680-861 trim tool assembly from the engine block. 18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-863 metal shaving catch plug. 19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline. 20. Using a light, illuminate the backside of the straight edge. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1679 21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary. 24. Install the piston and the connecting rod. Refer to Piston, Connecting Rod, and Bearing Installation. 25. Install the oil pan. Refer to Oil Pan Replacement. 26. Install the cylinder head. Refer to Cylinder Head Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1680 Cylinder Liner: Technical Service Bulletins Engine - Cylinder Bore Liner Installation Bulletin No.: 03-06-01-022A Date: January 21, 2004 INFORMATION Subject: Guidelines for Cylinder Bore Liner/Piston Sleeve Replacement on the L4 Ecotec Engine Models: 2002-2004 Chevrolet Cavalier 2004 Chevrolet Classic, Malibu 2002-2004 Oldsmoblie Alero 2002-2004 Pontiac Grand Am, Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 03-06-01-022 (Section 06 - Engine). Replacement of the cylinder bore liner is now a validated service repair process and an alternative to engine block or engine assembly replacement. Conditions for engine cylinder bore liner replacement are somewhat difficult to determine and may initially appear as other common customer concerns. Customer may comment on conditions such as: ^ Engine overheating ^ Engine coolant consumption ^ White smoke from vehicle exhaust ^ Poor heater performance ^ Excessive engine oil consumption ^ Unusual engine knocking noises All of the above conditions MAY be symptoms of a cylinder bore liner that needs replacement. Cylinder liner replacement determination should be made AFTER the cylinder head has been removed for inspection. Inspect the engine for the following conditions: SCUFFED CYLINDER LINER BORE DUE TO THE FOLLOWING: - Incorrect piston to bore clearance - Broken or incorrectly installed piston rings - Incorrectly seated or missing wrist pin clips causing the wrist pin to "walk out" CRACKED CYLINDER BORE LINER - Crack in the cylinder bore cylinder liner - Crack in the flange area cylinder liner "DROPPED" CYLINDER LINER FLANGE This "dropped" condition can be determined using a straight edge across the bore liner flange and block deck face. When there is clearance between the straight edge and the cylinder bore liner flange, the cylinder liner has dropped below the block deck face. EXCESSIVE CYLINDER BORE WEAR When the measured cylinder bore diameter exceeds the Service Manual specification, bore liner replacement is the service procedure. In any of these cases, the cylinder bore liner may be replaced instead of replacing the engine block or engine assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Engine - Revised Cylinder Sleeve Replacement Procedure > Page 1681 The procedure for replacing the cylinder bore liner is covered in the Service Information as well as Corporate Bulletin Number 03-06-01-018. Note: The Cylinder Bore Liner, P/N 88984129, inside diameter (I.D.) is fully machined and honed to size and is optimally finished as shipped from GMSPO. Any attempt to modify this factory produced sizing and finish with any additional boring or honing may lead to engine damage, excessive noise or abnormal oil consumption. Parts Information Parts are currently available from GMSPO. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1682 Cylinder Liner: Service and Repair The content of this article/image reflects the changes identified in TSB Bulletin No.: 03-06-01-018D Date: April 05, 2006 SERVICE MANUAL UPDATE Subject: New Cylinder Bore Piston Sleeve Replacement Procedure Models: 2002-2005 Chevrolet Cavalier 2004-2006 Chevrolet Classic, Malibu 2005-2006 Chevrolet Cobalt, Cobalt SS 2006 Chevrolet HHR 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Sunfire 2002-2006 Pontiac Grand Am 2005-2006 Pontiac G6, Pursuit (Canada Only) 2006 Pontiac Soltice with Ecotec 2.0L, 2.2L or 2.4L 4-Cylinder Engine (VINs P, F, B - RPOs LSJ, L61, LE5) Tools Required EN45680-850 Cylinder Sleeve Removal and Installation Kit Removal Procedure Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Note: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. Remove the cylinder head. 2. Remove the oil pan. 3. Remove the piston and connecting rod. 4. Inspect the condition of the piston. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1683 5. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 6. Install the EN 45680-852 cylinder bore sleeve puller (1) through the cylinder bore. Note: Ensure that the shoe is flat against the bottom of the cylinder bore liner or damage to the cylinder bore liner puller EN45680-852 will occur. 7. Align the shoe (1) of the EN 45680-852 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2). 8. Hold the threaded shaft of the EN 45680-852 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 9. Install the EN 456850-851 fixture (4) onto the threaded shaft of the EN 456850-852 cylinder bore sleeve puller and the engine block. 10. Install the bearing (3) and the nut (1). 11. Tighten the nut (1) to the bearing (3). 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 coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Use 4 old cylinder head bolts for the attaching bolts 12. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten the bolts to 15 N.m (11 lb-ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1684 13. Rotate the nut clockwise in order to remove the cylinder bore liner. Note: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. 14. Remove EN 45680-851 fixture, EN 45680-852 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block. 15. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Installation Procedure Note: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Note: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1685 1. Place the NEW cylinder bore sleeve onto the cylinder block. 2. Install EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve. 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 coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. Important: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the EN 45680-851 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten the 4 attachment bolts to 15 N.m (11 lb-ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1686 4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2). 5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2). 6. Align the pusher block (2) of EN 45680-853 cylinder bore sleeve installer into the groove of EN 45680-851 fixture (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1687 Note: Do not use any air powered or electric tools to rotate the threaded shaft of the fixture EN 45680-851/cylinder bore liner installer EN 45680-853 assembly or damage to the cylinder bore liner will occur. 7. Using a ratchet, rotate the threaded shaft of EN 45680-85 fixture and EN 45680-853 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block. 8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block. 9. Using a torque wrench, tighten the threaded shaft of the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly to 102 Nm (75 lb-ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1688 10. Remove the EN 45680-851 fixture and EN 45680-853 cylinder bore sleeve installer assembly (1) from the cylinder block (2). Cylinder Liner Trimming Note: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1689 Note: Ensure that all the metal particles are collected in order to prevent internal damage to the transaxle or bearings. 2. Place the EN 45680-863 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional EN 45680-863 metal shaving catch plugs into all remaining cylinder bore sleeves. NOTE: Installing the metal shaving catch plug EN 45680-863 deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure. Note: Installing the metal shaving catch plug EN 45680-863 above the recommended depth will cause damage to the metal shaving catch plug EN 45680-863. 4. Ensure that the EN 45680-863 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Important: Before using EN 45680-861 trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the EN 45680-862 set gage ring (1) should be positioned upward on a flat surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1690 Important: Ensure that the EN 45680-862 set gage ring surfaces are clean. 6. Carefully position EN 45680-861 trim tool assembly onto the EN 45680-862 set gage ring. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Important: Once this procedure is done, it is not necessary to reset the EN 45680-861 trim tool assembly height until the blades are worn or damaged 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten the shaft collar screw to 19 N.m (14 lb-ft). 10. Place the EN 45680-861 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block. 11. Install the EN 45680-864 4 bolts into the cylinder head bolt holes in the block. Tighten the bolts to 20 N.m (15 lb-ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1691 Note: For proper tool operation a drill motor with a 1/2 inch chuck 1-1/8 hp. 7 amps, triple gear reduction and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur. 12. Fasten the drive adapter EN 45680-866 into the drill chuck. Note: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage. 13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-861 trim tool assembly Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place the EN 45680-866 drive adapter and the drill assembly vertically onto the EN 45680-861 drive adapter end of trim tool assembly . Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove the EN 45680-866 drive adapter (1) and the drill assembly from the EN 45680-861 trim tool assembly. 16. Turn OFF the compressed air valve. 17. Remove the EN 45680-861 trim tool assembly from the engine block. 18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-863 metal shaving catch plug. 19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline. 20. Using a light, illuminate the backside of the straight edge. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Cylinder Liner > Component Information > Technical Service Bulletins > Page 1692 21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. 22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary. 24. Install the piston and the connecting rod. 25. Install the oil pan. 26. Install the cylinder head. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Engine Block Heater: Service and Repair Coolant Heater Coolant Heater Replacement Removal Procedure 1. Disconnect the coolant heater cord (1). 2. Remove the coolant heater bolt. 3. Remove the coolant heater. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 1697 1. Install the coolant heater. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant heater bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. Connect the coolant heater cord (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 1698 Engine Block Heater: Service and Repair Coolant Heater Cord Coolant Heater Cord Replacement Removal Procedure 1. Disconnect the engine coolant heater cord (1). 2. Remove the clips from the engine mount and surge tank. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 1699 1. Install the clips from the engine mount and surge tank. 2. Connect the engine coolant heater cord (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt First Pass ............................................................................................................................................. ................................................ 100 Nm (74 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 75 degrees Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1703 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement ^ Tools Required J 38122-A Harmonic Balancer Holder Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front tire and wheel. 3. Remove the front fender liner. 4. Remove the engine drive belt. 5. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. 6. Remover the crankshaft balancer bolt. Discard the bolt. 7. Remove the crankshaft balancer. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1704 1. Install the crankshaft balancer. 2. Install a NEW crankshaft balancer bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Use J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. ^ Tighten the bolt to 100 Nm (74 ft. lbs.) plus 75 degrees. 4. Install the engine drive belt. 5. Install the front fender liner. 6. Install the front tire and wheel. 7. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter @ 14.5 mm up .......................................................................................................................... 85.967-85.982 mm (13.3845-3.3851 inch) Piston to Bore Clearance ........................................................................................................................................... 0.010-0.041 mm (0.0004-0.0016 inch) Piston Weight ......................................................................... ................................................................................................................................................ Piston Height .................................................................................................................................................. ............................... Max. 0.9 mm-below deck Piston Pin Bore I.D. .............................................................................................................................................. 20.002-20.007 mm (0.7875-0.7877 inch) Ring Groove Width, Top .............................................................................................................................................. 1.23-1.25 mm (0.0484-0.0492 inch) Ring Groove Width, Second ......................................................................................................................................... 1.52-1.54 mm (0.0598-0.0606 inch) Ring Groove Width, Oil Control ................................................................................................................................... 2.52-2.54 mm (0.0992-0.1000 inch) Piston Ring Thickness, Top ................................................................................................................................... 1.170-1.190 mm (0.0461-0.0469 inch) Piston Ring Thickness, Second ................................................................................................................................. 1.471-1.490 mm (0.0579-0.0587 inch) Piston Ring Thickness, Oil Control Rail ........................................................................................................................... 0.43 mm max. (0.0169 in max.) Piston Ring Thickness, Oil Control Spacer ............................................................................................................... 1.574-1.651 mm (0.0620-0.0650 inch) Ring to Groove Clearance, Top .................................................................................................................................... 0.04-0.08 mm (0.0015-0.0031 inch) Ring to Groove Clearance, Second ........................................................................................................................... 0.030-0.069 mm (0.0012-0.0027 inch) Ring to Groove Clearance, Oil Control ..................................................................................................................... 0.090-0.106 mm (0.0035-0.0042 inch) Ring Gap, Top ................................................................................................... ................................................................ 0.20-0.40 mm (0.008-0.016 inch) Ring Gap, Second ............................................................................................................................................................. 0.35-0 55 mm (0.014-0.022 inch) Ring Gap, Oil Rails ........................................................................................................................................................... 0.25-0.76 mm (0.010-0.030 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin O.D. ..................................................................................................................................................... 19.995-20.000 mm (0.7872-0.7874 inch) Piston to Pin Clearance ............................................................................................................................................. 0.002-0.012 mm (0.0001-0.0005 inch) Pin to Rod Clearance ............................................................. .............................................................................................................. 0.007-0.026 mm Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Diameter @ 14.5 mm up .......................................................................................................................... 85.967-85.982 mm (13.3845-3.3851 inch) Piston to Bore Clearance ........................................................................................................................................... 0.010-0.041 mm (0.0004-0.0016 inch) Piston Weight ......................................................................... ................................................................................................................................................ Piston Height .................................................................................................................................................. ............................... Max. 0.9 mm-below deck Piston Pin Bore I.D. .............................................................................................................................................. 20.002-20.007 mm (0.7875-0.7877 inch) Ring Groove Width, Top .............................................................................................................................................. 1.23-1.25 mm (0.0484-0.0492 inch) Ring Groove Width, Second ......................................................................................................................................... 1.52-1.54 mm (0.0598-0.0606 inch) Ring Groove Width, Oil Control ................................................................................................................................... 2.52-2.54 mm (0.0992-0.1000 inch) Piston Ring Thickness, Top ................................................................................................................................... 1.170-1.190 mm (0.0461-0.0469 inch) Piston Ring Thickness, Second ................................................................................................................................. 1.471-1.490 mm (0.0579-0.0587 inch) Piston Ring Thickness, Oil Control Rail ........................................................................................................................... 0.43 mm max. (0.0169 in max.) Piston Ring Thickness, Oil Control Spacer ............................................................................................................... 1.574-1.651 mm (0.0620-0.0650 inch) Ring to Groove Clearance, Top .................................................................................................................................... 0.04-0.08 mm (0.0015-0.0031 inch) Ring to Groove Clearance, Second ........................................................................................................................... 0.030-0.069 mm (0.0012-0.0027 inch) Ring to Groove Clearance, Oil Control ..................................................................................................................... 0.090-0.106 mm (0.0035-0.0042 inch) Ring Gap, Top ................................................................................................... ................................................................ 0.20-0.40 mm (0.008-0.016 inch) Ring Gap, Second ............................................................................................................................................................. 0.35-0 55 mm (0.014-0.022 inch) Ring Gap, Oil Rails ........................................................................................................................................................... 0.25-0.76 mm (0.010-0.030 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1723 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1724 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing > Component Information > Specifications Camshaft Housing: Specifications Cam Cover to Cylinder Head Bolt ........................................................................................................................................................ 10 Nm (89 inch lbs.) Cam Cover to Ground Cable Bolt ......................................................................................................................................................... 10 Nm (89 inch lbs.) Cam Cover to Ground Cable Stud ......................................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts ................................................................................................................................. .................................................... 25 Nm (19 ft. lbs.) Stationary Lash Adjuster Bore I.D. .................................................................................................................... 12.013-12.037 mm (0.4730-0.4739 inch) Stationary Lash Adjuster O.D. .............................................................................................................................. 11.986-12.000 mm (0.0005-0.0020 inch) Stationary Lash Adjuster Clearance ....................................................................................................................... 0.013-0.051 mm (3.2210-3.2299 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke Valve Cover: Customer Interest Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1739 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1740 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Customer Interest for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1741 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke Valve Cover: All Technical Service Bulletins Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1747 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1748 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Cover: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1749 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 1750 Valve Cover: Specifications Rocker Arm Cover Bolts ...................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 1751 Valve Cover: Service and Repair Camshaft Cover Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the air outlet resonator. 3. Remove the accelerator and cruise control cables bracket. 4. Remove the PCV hose. 5. Remove the fuel line brackets. 6. Remove the brake booster hose/pipe from its bracket. 7. Remove the ignition coil and module assembly. 8. Remove the ground strap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 1752 9. Remove the camshaft cover bolts. 10. Remove the camshaft cover. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the camshaft cover and bolts. ^ Tighten the camshaft bolts to 10 Nm (89 inch lbs.). 2. Install the ground strap. ^ Tighten the ground strap bolt to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Page 1753 3. Install the ignition coil and module assembly. ^ Tighten the ignition coil and module assembly bolt to 10 Nm (89 inch lbs.). 4. Install the brake booster hose/pipe to its bracket. 5. Install the fuel line bracket. ^ Tighten the fuel line bracket bolt to 10 Nm (89 inch lbs.). 6. Install the accelerator and cruise control cables bracket. ^ Tighten the accelerator and cruise control cables bracket bolt to 10 Nm (89 inch lbs.). 7. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide I.D., Intake ........................................................................................................................................... 6.000-6.012 mm (0.2362-0.2367 inch) Valve Guide I.D., Exhaust ........................................................................................................................................ 6.000-6.012 mm (0.2362-0.2367 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Run-out ............................................................................................................................. .................................... 0.05 mm max. 0.0020 in max. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Load @ 32.5 mm, Closed .................................................................................................................................... 245.0-271.0 N. - Eng. Spec. Valve Spring Load @ 32.5 mm, Open ....................................................................................................................................... 525.0-575.0 N. - Eng. Spec. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1763 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 43649 Valve Spring Compressor - J 36017 Valve Guide Seal Remover Removal Procedure 1. Remove the camshaft. 2. Remove the camshaft roller followers. 3. Install the J 43649 to the cylinder head. 4. Remove the spark plugs. 5. Install an air hose adapter into the spark plug hole. 6. Pressurize the cylinder to 690 kPa (100 psi). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1764 7. Compress the valve spring. 8. Remove the valve spring keepers. 9. Remove the valve spring. 10. Using the J36017 to remove the valve seal. Installation Procedure 1. Using the J36017 to install the valve seal. 2. Install the valve spring. 3. Compress the valve spring. 4. Install the valve spring keepers. 5. Remove the air hose adapter into the spark plug hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 1765 6. Remove the J 43649 from the cylinder head. 7. Install the spark plugs. 8. Install the camshaft roller followers. 9. Install the camshaft. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Stem O.D., Intake ........................................................................................................................................... 5.955-5.970 mm (0.2344-0.2355 inch) Valve Stem O.D., Exhaust ......................................................................................................................................... 5.935-5.950 mm (0.2337-0.2343 inch) Stem to Guide Clearance, Intake ............................................................................................................................... 0.030-0.057 mm (0.0012-0.0022 inch) Stem to Guide Clearance, Exhaust ............................................................................................................................ 0.050-0.077 mm (0.0020-0.0026 inch) Valve Stem Installed Heights ............................................................................ ........................................................................................ Check and Record Valve Face Run-out ............................................................................................................................................................. 0.04 mm max. 0.0016 in max. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1774 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1775 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1776 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Drive Belt Routing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Drive Belt Routing > Page 1779 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1780 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: ^ The drive belt ^ The drive belt tensioner ^ The drive belt idler pulley ^ The crankshaft balancer pulley ^ The accessory drive component mounting brackets ^ The accessory drive components The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1783 is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1784 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1785 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1786 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1787 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step number on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1788 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt by one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Drive Belt Falls Off Drive Belt Falls Off Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1789 Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may have occurred to the drive belt when the drive belt fell off. The drive belt may have been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Drive Belt Rumbling Drive Belt Rumbling Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1790 Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Drive Belt Squeal Drive Belt Squeal Diagnosis Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1791 Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1792 Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Drive Belt Whine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1793 Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 1794 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the front fender liner. 3. Rotate the drive belt tensioner counter-clockwise to release the spring tension. 4. Remove the drive belt. Installation Procedure 1. Rotate the drive belt tensioner counter-clockwise to release the spring tension. 2. Install the drive belt. 3. Install the front fender liner. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolt ..................................................................................................................... .................................................... 45 Nm (33 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1798 Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis ^ Tools Required J 23600-B Belt Tension Gauge 1. Run the engine, with no accessories on, until the engine is warmed up. Shut the engine off and read the belt tension using the J23600-B placed halfway between the generator and the power steering pump. Note the reading and remove the J 23600-B. 2. Start the engine with the accessories off and allow the system to stabilize for 15 seconds. Turn the engine off. Using a 15 mm socket, apply clockwise force (tighten) to the tensioner pulley bolt. Release the force and immediately take a tension reading without disturbing belt tensioner position. 3. Using the same wrench, apply a counterclockwise force to the tensioner pulley bolt and raise the pulley to eliminate all tension. Slowly lower the pulley to the belt and take a tensioner reading without disturbing the belt tensioner position. 4. Average the three readings. If the average of the three readings is not between 133 - 222 N (30 50 lbs.) and the bolt is within the tensioners operating range, replace the tensioner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 1799 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement ^ Tools Required J 45025 Torque Wrench Adapter Removal Procedure 1. Remove the drive belt. 2. Remove the drive belt tensioner bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. Important: In order to obtain the proper torque when using any torque wrench adapter you must use the following formula: Pre-set Torque = Torque Wrench Length x Torque Desired divided by Torque Wrench Length + Extension Length. 2. Install the drive belt tensioner bolt. ^ Use a J 45025 Torque Wrench Adapter to tighten the drive belt tensioner bolt. ^ Tighten the drive belt tensioner bolt to 45 Nm (33 ft. lbs.). 3. Install the drive belt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications Engine Mount: Specifications Engine Bracket to Mount Bolt .............................................................................................................. .................................................... 60 Nm (44 ft. lbs.) Final Pass 90 degrees Engine Mount to Body Nut ....................................................................................................................................................... ................ 75 Nm (55 ft. lbs.) Engine Mount Strut Bolts ...................................................................... ................................................................................................. 100 Nm (74 ft. lbs.) Final Pass 90 degrees Engine Mount Strut Bracket Bolts ............................................................................................................................................................ 66 Nm (49 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Specifications > Page 1803 Engine Mount: Testing and Inspection Engine Mount Inspection Important: It is the design intent of the torque axis mounting systems to allow more engine movement than other mounting systems. Do not replace any torque axis mounts for excessive engine movement. Replace them if damage exists on the mount or rubber. 1. Raise the engine enough to apply slight tension on the engine mount. 2. Replace the engine mount if any of the following conditions exist: ^ The hard rubber surface is covered with heat cracks. ^ The rubber split through the center. 3. Lower the engine. 4. Verify the engine mount fastener torque. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement Engine Mount: Service and Repair Engine Mount Bracket Replacement Engine Mount Bracket Replacement Removal Procedure 1. Remove the engine mount. 2. Raise the engine enough to gain clearance in order to remove the upper bracket bolts (1). 3. Loosen the lower bracket bolt and remove the bracket (2) and the bolt together. Installation Procedure 1. Install the lower bolt into the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1806 2. Install the bracket (2) to the engine and hand tighten the lower bolt. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the upper bracket bolts (1). ^ Tighten all the bolts to 110 Nm (81 ft. lbs.). 4. Install the engine mount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1807 Engine Mount: Service and Repair Engine Mount Replacement Engine Mount Replacement Removal Procedure 1. Remove the cruise control module mounting nuts. 2. Remove the A/C low pressure line retaining bracket (1) nut. 3. Using a block of wood between the floor jack and the oil pan, support the engine. 4. Remove the engine mount (2) to bracket bolts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1808 5. Remove the engine mount to body nuts (1). 6. Remove the engine mount. Installation Procedure 1. Install the engine mount to the vehicle. 2. Align the engine mount (2) to the mount bracket using a dowel (1). 3. Hand tighten the engine mount to body nuts (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1809 4. Install the engine mount (2) to bracket bolts (1). Notice: Refer to Fastener Notice in Service Precautions. ^ Tighten the engine mount to body nuts and the engine mount to bracket bolts to 55 Nm (41 ft. lbs.). ^ Tighten the engine mount bolts to 110 Nm (81 ft. lbs.). 5. Install the A/C low pressure line retaining bracket (1) nut. ^ Tighten the nut to 10 Nm (89 inch lbs.). 6. Install the cruise control module mounting nuts. ^ Tighten the nuts to 10 Nm (89 inch lbs.). 7. Remove the floor jack. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1810 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement Engine Mount Strut Bracket Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right engine splash shield. 3. Remove the engine mount strut. 4. Remove the engine mount strut bracket bolts. 5. Remove the engine mount strut bracket. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine mount strut bracket and the bolts. ^ Tighten the engine mount strut bracket bolts to 66 Nm (49 ft. lbs.). 2. Install the engine mount strut. 3. Install the right engine splash shield. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 1811 Engine Mount: Service and Repair Engine Mount Strut Replacement Engine Mount Strut Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the right engine splash shield. 3. Remove the engine mount strut bolts. 4. Remove the engine mount strut. Installation Procedure 1. Install the engine mount strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount strut bolts. ^ Tighten the engine mount strut bolts to 100 Nm (74 ft. lbs.) + 90 degrees. 3. Install the right engine splash shield. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure @ 1,000 RPM .................................................................................................................................................. 344.75-551.60 Kpa (50-80 Psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1816 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing After running the vehicle for a few minutes on a level surface, turn the engine off and allow for adequate drain-down time (2-3 minutes) and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. Run the engine and verify low or no oil pressure on the vehicle gauge or light. Listen for a noisy valve train or a knocking noise. Inspect for the following: - Oil contamination - Oil diluted by moisture or unburned fuel mixtures - Improper oil viscosity for the expected temperature - Incorrect or malfunctioning oil pressure sensor - Incorrect or malfunctioning oil pressure gauge - Plugged oil filter - Malfunctioning oil bypass valve Remove the oil pressure sender or another engine block oil gallery plug. Install an oil pressure gage and measure the engine oil pressure. Compare the readings to specifications. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty - GOil pump-to-engine front cover bolts loose - Oil pump screen loose, plugged, or damaged - Oil pump screen O-ring seal missing or damaged - Malfunctioning oil pump pressure regulator valve - Excessive bearing clearance - Cracked, porous or restricted oil galleries - Oil gallery plugs missing or incorrectly installed - Broken lash adjusters Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke Engine Oil Dip Stick - Dip Stick Tube: Customer Interest Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1825 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1826 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Customer Interest for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1827 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke Engine Oil Dip Stick - Dip Stick Tube: All Technical Service Bulletins Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1833 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1834 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Oil Dip Stick - Dip Stick Tube: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1835 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 1836 Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Fill Tube ......................................................................................................................................... .................................................... 50 Nm (37 ft. lbs.) Dipstick Guide to Intake Manifold Bolt ................................................................................................................................................ 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Technical Service Bulletins > Page 1837 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Unclip the electrical wiring harness from the oil level indicator tube. 3. Remove the oil level indicator tube bolt (1). 4. Remove the oil level indicator tube (3). 5. Remove the oil level indicator tube seal (2). Installation Procedure 1. Install the oil level indicator tube seal (2). 2. Install the oil level indicator tube (3). 3. Clip the electrical wiring harness to the oil level indicator tube. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the oil level indicator tube bolt (1). ^ Tighten the oil level indicator tube bolt to 10 Nm (89 inch lbs.). 5. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug ............................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1845 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1846 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter Change ............................................................................................................................... ............................................................. 4.8L (5.0 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1849 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... .......................................................................................................................... 10W-30, 5W-30 (preferred) Below -29° C (-20° F) ................................................................................................................................................. 5W-30 synthetic (preferred) , 0W-30 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1850 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. DO NOT use an open end wrench on the hex on top of the oil filter cap. 5. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1851 6. Remove the oil filter cap with filter. 7. Remove the filter from the cap. Installation Procedure 1. Install the filter to the cap. 2. Install the oil filter cap with filter. 3. DO NOT use an open end wrench on the hex on top of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1852 Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. 4. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the engine with oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Description and Operation Oil Cooler: Description and Operation Engine Oil Cooler The engine oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The engine oil temperature is controlled by the temperature of the engine coolant that surrounds the oil cooler in the radiator. The engine oil pump, pumps the oil through the engine oil cooler line to the oil cooler. The oil then flows through the cooler where the engine coolant absorbs heat from the oil. The oil is then pumped through the oil cooler return line, to the oil filter, to the engine block oil system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1860 Oil Filter: Specifications Oil Filter ............................................................................................................................................... .................................................... 17 Nm (13 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1861 Oil Filter: Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1862 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1863 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. DO NOT use an open end wrench on the hex on top of the oil filter cap. 5. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1864 6. Remove the oil filter cap with filter. 7. Remove the filter from the cap. Installation Procedure 1. Install the filter to the cap. 2. Install the oil filter cap with filter. 3. DO NOT use an open end wrench on the hex on top of the oil filter cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1865 Notice: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Notice: Refer to Fastener Notice in Service Precautions. 4. Use a 32 mm (1 1/4 inch) socket (1) on the hex on the top of the oil filter cap, or an Oil Filter Wrench on the outside diameter of the oil filter cap. ^ Tighten the oil filter cap until fully seated, DO NOT exceed 25 Nm (18 ft. lbs.). 5. Install the oil pan drain plug. ^ Tighten the oil pan drain plug to 25 Nm (18 ft. lbs.). 6. Lower the vehicle. 7. Fill the engine with oil. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter .................................................................................................................................. ................................................... 35 Nm (26 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Housing > Component Information > Specifications Oil Filter Housing: Specifications Oil Filter Housing Cover ...................................................................................................................... .................................................... 22 Nm (16 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan to Block Bolts .......................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1875 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the engine oil. 3. Remove the engine mount strut bracket. 4. Remove the lower AC compressor bolt. 5. Loosen the upper AC compressor bolts. 6. Remove the oil pan bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1876 7. Remove the oil pan Installation Procedure 1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris. 2. Apply a 2 mm bead of RTV GM P/N United States 12346286, GM P/N Canada 10953472 around the perimeter of the oil pan and the oil suction port opening. Do not over apply the RTV. More than a 2 mm bead is not required. 3. Install the oil pan. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the oil pan bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1877 ^ Tighten the oil pan bolts to 25 Nm (18 ft. lbs.). 5. Install the AC compressor bolts. 6. Install the engine mount strut bracket. 7. Lower the vehicle. 8. Fill the engine oil to the proper level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1881 Oil Pressure Sender: Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1882 Crankshaft Position Sensor,Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1883 Engine Oil Pressure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1884 Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1885 Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 1886 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the engine oil pressure sensor electrical connector. 4. Remove the engine oil pressure sensor. Installation Procedure 1. Install the engine oil pressure sensor. 2. Connect the engine oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Bolt ............................................................................................................................ ................................................... 6 Nm (53 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Drive Shaft > Component Information > Specifications Oil Pump Drive Shaft: Specifications Oil Pump Drive Assembly .................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure @ 1,000 RPM .................................................................................................................................................. 344.75-551.60 Kpa (50-80 Psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1897 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing After running the vehicle for a few minutes on a level surface, turn the engine off and allow for adequate drain-down time (2-3 minutes) and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. Run the engine and verify low or no oil pressure on the vehicle gauge or light. Listen for a noisy valve train or a knocking noise. Inspect for the following: - Oil contamination - Oil diluted by moisture or unburned fuel mixtures - Improper oil viscosity for the expected temperature - Incorrect or malfunctioning oil pressure sensor - Incorrect or malfunctioning oil pressure gauge - Plugged oil filter - Malfunctioning oil bypass valve Remove the oil pressure sender or another engine block oil gallery plug. Install an oil pressure gage and measure the engine oil pressure. Compare the readings to specifications. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: - Oil pump worn or dirty - GOil pump-to-engine front cover bolts loose - Oil pump screen loose, plugged, or damaged - Oil pump screen O-ring seal missing or damaged - Malfunctioning oil pump pressure regulator valve - Excessive bearing clearance - Cracked, porous or restricted oil galleries - Oil gallery plugs missing or incorrectly installed - Broken lash adjusters Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke Intake Manifold: Customer Interest Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1906 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1907 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-003C > Oct > 05 > Engine - Excessive Oil Consumption/Blue Exhaust Smoke > Page 1908 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 00-06-01-026C > Feb > 10 > Engine Intake Manifold Inspection/Replacement Intake Manifold: All Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05-06-01-003C > Oct > 05 > Engine Excessive Oil Consumption/Blue Exhaust Smoke Intake Manifold: All Technical Service Bulletins Engine - Excessive Oil Consumption/Blue Exhaust Smoke Bulletin No.: 05-06-01-003C Date: October 17, 2005 TECHNICAL Subject: Excessive Oil Consumption, Blue Smoke on Acceleration (Inspect Intake Manifold and/or Cam Cover, Replace if Necessary) Models: 2004-2005 Chevrolet Cavalier, Classic, Malibu 2005 Chevrolet Cobalt 2004 Oldsmobile Alero 2004-2005 Pontiac Grand Am, Sunfire 2005 Pontiac Pursuit (Canada Only) 2004-2005 Saturn L-Series, ION, VUE with Ecotec 2.2L 4-Cylinder Engine (VINs D, F - RPO L61) Attention: This bulletin covers any vehicle with the Ecotec 2.2L L61 engine built during calendar year 2004. Supercede: This bulletin is being revised to add additional warranty information. Please discard Corporate Bulletin Number 05-06-01-003B (Section 06 - Engine/Propulsion System). Condition Some customers may comment on excessive oil consumption or blue smoke on acceleration. Excessive oil consumption, not due to leaks, is the use of 0.9L (1 qt) or more of engine oil within 3200 km (2,000 mi). Cause Incorrect sizing of the PCV orifice and/or misalignment of the oil baffle in the cam cover may allow higher than desired amounts of oil into the combustion chamber. Correction Important: If the following information in this bulletin does not resolve the concern, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Inspect the cam cover for heat stake marks and inspect the intake manifold for PCV orifice size. Replace either, as necessary, based on inspection. Follow the procedures below. Camshaft Cover Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05-06-01-003C > Oct > 05 > Engine Excessive Oil Consumption/Blue Exhaust Smoke > Page 1918 1. Remove the camshaft cover and inspect for heat stake marks in the locations shown. Refer to Camshaft Cover Removal in the appropriate Service Information (SI) procedures. Important: The oil fill tube must be replaced along with the camshaft cover for the following models: ^ 2005 Chevrolet Cobalt ^ 2005 Pontiac Pursuit ^ 2005 Saturn ION 1. If the heat stake marks are not present, replace the camshaft cover with a new one. 2. If the heat stake marks are present, re-install the camshaft cover on the engine. Refer to Camshaft Cover Installation in the appropriate Service Information (SI) procedures. Intake Manifold 1. Remove the intake manifold from the cylinder head. Refer to Intake Manifold Removal in the appropriate Service Information (SI) procedures. 2. Attempt to insert the chuck end of a 2.0 mm (5/64 in) drill bit into the PCV orifice where shown. The orifice is slightly below the surface. 3. If the chuck end of the drill bit can be inserted, replace the intake manifold with a new one. 4. If the chuck end of the drill bit cannot be inserted, re-install the intake manifold to the cylinder head. Refer to Intake Manifold Installation in the appropriate Service Information (SI) procedures. 5. If the information in this bulletin did not correct the excessive oil consumption condition, refer to Oil Consumption Diagnosis in the appropriate Service Information (SI) procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05-06-01-003C > Oct > 05 > Engine Excessive Oil Consumption/Blue Exhaust Smoke > Page 1919 Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 05-06-01-003C > Oct > 05 > Engine Excessive Oil Consumption/Blue Exhaust Smoke > Page 1920 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intake Manifold: > 00-06-01-026C > Feb > 10 > Engine - Intake Manifold Inspection/Replacement Intake Manifold: All Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1926 Intake Manifold: Specifications Intake Manifold to Cylinder Head Bolt ................................................................................................................................................. 10 Nm (89 inch lbs.) Intake Manifold to Cylinder Head Nut .................................................................................................................................................. 10 Nm (89 inch lbs.) Intake Manifold to Cylinder Head Stud .................................................................................................................................................. 6 Nm (53 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1927 Intake Manifold: Service and Repair Intake Manifold Replacement Removal Procedure Intake Manifold And Components 1. Remove the air inlet duct and resonator. 2. Disconnect the IAC electrical connector. 3. Disconnect the TPS electrical connector. 4. Disconnect the MAP sensor electrical connector. 5. Disconnect the EVAP hose. 6. Disconnect the PCV hose. 7. Disconnect the purge solenoid tube. 8. Disconnect the brake booster hose. 9. Remove the oil level indicator tube bolt. 10. Disconnect the accelerator and cruise control cables. 11. Remove the throttle body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1928 12. Remove the fuel rail. 13. Remove the knock sensor connector from the intake manifold. 14. Remove the intake manifold nuts and bolts. 15. Remove the intake manifold. 16. Remove the intake manifold gasket, if necessary. The gasket is reusable if the gasket is not damaged. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1929 1. If removed, install the intake manifold gasket. 2. Install the intake manifold. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the intake manifold nuts and bolts. ^ Tighten the intake manifold nuts and bolts to 10 Nm (89 inch lbs.). 4. Install the knock sensor connector to the intake manifold. 5. Install the fuel rail. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1930 Intake Manifold And Components 6. Install the throttle body. 7. Connect the IAC electrical connector. 8. Connect the TPS electrical connector. 9. Connect the MAP sensor electrical connector. 10. Connect the EVAP hose. 11. Connect the PCV hose. 12. Connect the purge solenoid tube. 13. Connect the brake booster hose. 14. Install the oil level indicator tube bolt. 15. Connect the accelerator and the cruise control cables. Install the air inlet duct and resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement ^ Tools Required J 42067 Rear Main Seal installer Removal Procedure 1. Remove the transmission. 2. Remove the flywheel. Important: Make sure not to damage the outside diameter of the crankshaft or chamber with any tool. 3. Pry the crankshaft rear oil seal with a flat bladed tool. Installation Procedure 1. Use the J 42607 and install the seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 1935 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the flywheel. ^ Tighten the flywheel bolts to 53 Nm (39 ft. lbs.) plus 25 degrees. 3. Install the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest: > 04-06-01-009A > Nov > 05 > Engine Oil Leaks From the Front Crank Seal When Cold Front Crankshaft Seal: Customer Interest Engine - Oil Leaks From the Front Crank Seal When Cold Bulletin No.: 04-06-01-009A Date: November 01, 2005 TECHNICAL Subject: Oil Leak from Engine Front Cover Crankshaft Oil Seal During Extremely Cold Weather (Replace Crankshaft Front Oil Seal) Models: 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2004-2005 Chevrolet Malibu 2005-2005 Chevrolet Cobalt 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire 2005-2005 Pontiac Pursuit (Canada Only) 2000-2005 Saturn L-Series 2002-2005 Saturn ION, VUE with 2.2L Ecotec Four-Cylinder Engine (VINs D, F - RPO L61) Supercede: This bulletin is being revised to add additional models and model years, update the information and title, and correct the Parts Information. Please discard Corporate Bulletin Number 04-06-01-009 (Section 06 - Engine Mechanical). Condition Some customers may comment on an oil leak from the front engine cover crankshaft oil seal during extremely cold weather. Cause During extremely cold weather, moisture at the engine crankshaft balancer may freeze to the crankshaft front oil seal, which may result in the oil seal being torn when the engine is started. Correction Replace front crankshaft oil seal with a new service part, P/N 12584041, which is constructed of an improved sealing compound that is not susceptible to freezing. Refer to the service procedure in this bulletin to replace the front crankshaft oil seal. Service Procedure Removal 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in the appropriate Service Manual or SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Customer Interest: > 04-06-01-009A > Nov > 05 > Engine Oil Leaks From the Front Crank Seal When Cold > Page 1944 2. Use a flat-bladed tool to remove the front crankshaft oil seal from the engine front cover. Discard the old front crankshaft oil seal. Installation 1. Use the front crankshaft seal installer, J 35268-A to install the new crankshaft front oil seal, P/N 12584041, to the engine front cover. 2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in the appropriate Service Manual or SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-01-009A > Nov > 05 > Engine - Oil Leaks From the Front Crank Seal When Cold Front Crankshaft Seal: All Technical Service Bulletins Engine - Oil Leaks From the Front Crank Seal When Cold Bulletin No.: 04-06-01-009A Date: November 01, 2005 TECHNICAL Subject: Oil Leak from Engine Front Cover Crankshaft Oil Seal During Extremely Cold Weather (Replace Crankshaft Front Oil Seal) Models: 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2004-2005 Chevrolet Malibu 2005-2005 Chevrolet Cobalt 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire 2005-2005 Pontiac Pursuit (Canada Only) 2000-2005 Saturn L-Series 2002-2005 Saturn ION, VUE with 2.2L Ecotec Four-Cylinder Engine (VINs D, F - RPO L61) Supercede: This bulletin is being revised to add additional models and model years, update the information and title, and correct the Parts Information. Please discard Corporate Bulletin Number 04-06-01-009 (Section 06 - Engine Mechanical). Condition Some customers may comment on an oil leak from the front engine cover crankshaft oil seal during extremely cold weather. Cause During extremely cold weather, moisture at the engine crankshaft balancer may freeze to the crankshaft front oil seal, which may result in the oil seal being torn when the engine is started. Correction Replace front crankshaft oil seal with a new service part, P/N 12584041, which is constructed of an improved sealing compound that is not susceptible to freezing. Refer to the service procedure in this bulletin to replace the front crankshaft oil seal. Service Procedure Removal 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in the appropriate Service Manual or SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-06-01-009A > Nov > 05 > Engine - Oil Leaks From the Front Crank Seal When Cold > Page 1950 2. Use a flat-bladed tool to remove the front crankshaft oil seal from the engine front cover. Discard the old front crankshaft oil seal. Installation 1. Use the front crankshaft seal installer, J 35268-A to install the new crankshaft front oil seal, P/N 12584041, to the engine front cover. 2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in the appropriate Service Manual or SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1956 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1957 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1958 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1964 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1965 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Front Crankshaft Seal: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1966 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Technical Service Bulletins > Page 1967 Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement ^ Tools Required J 35268-A Camshaft/Front Main Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Use a flat bladed tool to remove the seal from the front cover. Installation Procedure 1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover. 2. Install the crankshaft balancer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement ^ Tools Required J 43649 Valve Spring Compressor - J 36017 Valve Guide Seal Remover Removal Procedure 1. Remove the camshaft. 2. Remove the camshaft roller followers. 3. Install the J 43649 to the cylinder head. 4. Remove the spark plugs. 5. Install an air hose adapter into the spark plug hole. 6. Pressurize the cylinder to 690 kPa (100 psi). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1971 7. Compress the valve spring. 8. Remove the valve spring keepers. 9. Remove the valve spring. 10. Using the J36017 to remove the valve seal. Installation Procedure 1. Using the J36017 to install the valve seal. 2. Install the valve spring. 3. Compress the valve spring. 4. Install the valve spring keepers. 5. Remove the air hose adapter into the spark plug hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 1972 6. Remove the J 43649 from the cylinder head. 7. Install the spark plugs. 8. Install the camshaft roller followers. 9. Install the camshaft. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1977 Oil Pressure Sender: Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1978 Crankshaft Position Sensor,Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1979 Engine Oil Pressure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1980 Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1981 Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 1982 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the engine oil pressure sensor electrical connector. 4. Remove the engine oil pressure sensor. Installation Procedure 1. Install the engine oil pressure sensor. 2. Connect the engine oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component Information > Specifications Balance Shaft: Specifications Balance Shaft Bearing Carrier Bore in Block I.D. ................................................................................................ 42.000-42.016 mm (1.6535-1.6542 inch) Balance Shaft Bearing Carrier O.D. ...................................................................................................................... 41.975-41.995 mm (1.6526-1.6534 inch) Balance Shaft Housing to Block Clearance ............................................................................................................... 0.005-0.041 mm (0.0002-0.0016 inch) Balance Shaft Bearing I.D. #1 ............................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 inch) Balance Shaft Bearing I.D. #2 ............................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 inch) Balance Shaft Journal O.D. #1 .............................................................................................................................. 20.000-20.020 mm (0.7874-0.7882 inch) Balance Shaft Journal O.D. #2 .............................................................................................................................. 36.723-36.743 mm (1.4458-1.4466 inch) Balance Shaft Bearing Clearance #1 .......................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 inch) Balance Shaft Bearing Clearance #2 .......................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 inch) Balance Shaft End Play ............................................................................................................................................. 0.100-0.300 mm (0.0020-0.0118 inch) Balance Shaft Chain Length .......................................................................................................................... 368.622-369.032 mm (14.5127-14.5288 inch) Balance of Shafts .......................................................................................... .......................................................................... 4.05 Kg/mm per shaft, +/-6 % Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Bearing > Component Information > Specifications Balance Shaft Bearing: Specifications Balance Shaft Bearing Carrier to Block Bolt ........................................................................................................................................ 10 Nm (89 inch lbs.) Balance Shaft Bearing Carrier Bore in Block I.D. ................................................................................................ 42.000-42.016 mm (1.6535-1.6542 inch) Balance Shaft Bearing Carrier O.D. ...................................................................................................................... 41.975-41.995 mm (1.6526-1.6534 inch) Balance Shaft Bearing I.D. #1 ............................................................................................................................... 20.050-20.063 mm (0.7894-0.7899 inch) Balance Shaft Bearing I.D. #2 ............................................................................................................................... 36.776-36.825 mm (1.4479-1.4498 inch) Balance Shaft Bearing Clearance #1 .......................................................................................................................... 0.030-0.063 mm (0.0012-0.0025 inch) Balance Shaft Bearing Clearance #2 .......................................................................................................................... 0.033-0.102 mm (0.0013-0.0040 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Guide > Component Information > Specifications Balance Shaft Chain Guide: Specifications Balance Shaft Adjustable Chain Guide Bolt ......................................................................................................................................... 10 Nm (89 inch lbs.) Balance Shaft Fixed Chain Guide Bolt .................................................................................................................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Gear > Component Information > Specifications Balance Shaft Gear: Specifications Balance Shaft Sprocket Bolt ................................................................................................................ ..................................................... 50 Nm (37 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt First Pass ............................................................................................................................................. .................................................. 85 Nm (63 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 30 degrees Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Timing Chain Oil Nozzle Bolt .............................................................................................................................................................. 10 Nm (89 inch lbs.) Timing Chain Length .................................................................................................................................... 477.367-477.817 mm (18.7940-18.8117 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2002 Timing Chain: Service and Repair Timing Chain, Sprockets, and/or Tensioner Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the camshaft cover. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the engine front cover. 5. Rotate the engine until the crankshaft sprocket mark aligns with the second silver link (2) at the 5 o'clock position. 6. Lower the vehicle. 7. Remove the camshaft cover. 8. Ensure that the INT diamond on the intake camshaft sprocket is aligned with the copper link at (1) at the 2 o'clock position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2003 9. Ensure that the EXH triangle on the exhaust camshaft sprocket is aligned with the silver link (3). 10. Remove the timing chain tensioner. 11. Remove the timing chain tensioner guide. 12. Remove the engine mount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2004 13. Remove the fixed timing chain guide access plug. 14. Remove the fixed timing chain guide. 15. Remove the upper timing chain guide. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2005 16. Use a 24 mm wrench to hold the camshafts from turning. 17. Remove the exhaust camshaft sprocket bolt and discard. 18. Remove the exhaust camshaft sprocket. 19. Remove the intake camshaft sprocket bolt and discard. 20. Remove the intake camshaft sprocket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2006 21. Remove the timing chain through the top of the cylinder head. 22. Remove the crankshaft sprocket. 23. Remove the balance shaft drive chain tensioner. 24. Remove the adjustable balance shaft chain guide. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2007 25. Remove the small balance shaft drive chain guide. 26. Remove the upper balance shaft drive chain guide. Notice: It may ease removal of the balance shaft drive chain to get all of the slack in the chain between the crankshaft and water pump sprockets. 27. Remove the balance shaft drive chain. Installation Procedure ^ Tools Required J 45027 Tensioner Tool Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2008 Important: If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise. Notice: Refer to Fastener Notice in Service Precautions. 1. Install the upper balance shaft chain guide. ^ Tighten the upper balance shaft chain guide bolts to 10 Nm (89 inch lbs.). 2. Install the small balance shaft chain guide. 3. Tighten the balance shaft chain guide bolts. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). 4. Install the adjustable balance shaft drive chain guide. ^ Tighten the chain guide bolts to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2009 5. Turn the tensioner plunger 90 degrees in its bore and compress the plunger until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger. 6. Install the timing chain tensioner. 7. Tighten the chain tensioner bolts. ^ Tighten the chain tensioner bolts to 10 Nm (89 inch lbs.). 8. Remove the paper clip from the balance shaft drive chain tensioner. 9. Install the crankshaft sprocket with timing mark at the 5 o'clock position. 10. Lower the timing chain through the opening in the top of the cylinder head. Carefully ensure that the chain goes around both sides of the cylinder block bosses (1,2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2010 11. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position. 12. Hand tighten a NEW intake camshaft sprocket bolt. 13. Route the timing chain around the crankshaft sprocket with the second silver link aligning with the timing mark. 14. Route the timing chain around the intake camshaft sprocket with the copper colored link (1) aligning with the INT diamond. 15. Install the timing chain tensioner guide through the opening in the top of the cylinder head. ^ Tighten the timing chain tensioner guide bolt to 10 Nm (89 inch lbs.). 16. Install the exhaust camshaft sprocket with the timing chain silver link (3) at EXH triangle aligned at the 10 o'clock position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2011 17. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft. 18. Hand tighten the NEW exhaust camshaft sprocket bolt. 19. Install the fixed timing chain guide. ^ Tighten the fixed timing chain bolts to 10 Nm (89 inch lbs.). 20. Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) compound to thread and install the timing chain guide bolt access hole plug. ^ Tighten the access hole plug to 40 Nm (30 ft. lbs.). 21. Install the engine mount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2012 22. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner. 23. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 inch) (a) from end to end. 24. If the timing chain tensioner is not in the compressed state, perform the following steps: 24.1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. 24.2. Install the J 45027-2 (2) into a vise. 24.3. Install the notch end of the piston assembly into the J 45027-2 (2). 24.4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston. 25. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint free cloth. 26. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again. 27. At this point the tensioner should measure approximately 72 mm (2.83 inch) (a) from end to end. If the tensioner does not read 72 mm (2.83 inch) (a) from end to end repeat steps 16.1 and 16.4. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2013 28. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head. 29. Install the new timing chain tensioner assembly. ^ Tighten the timing chain tensioner to 75 Nm (55 ft. lbs.). 30. The timing chain tensioner is released by compressing it 2 mm (0.079 inch) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner. 31. Use a 24 mm wrench to hold the camshaft. ^ Tighten the NEW camshaft bolts to 85 Nm (63 ft. lbs.) plus 30 degrees. 32. Install the camshaft cover. 33. Raise the vehicle. 34. Install the engine front cover. 35. Lower the vehicle. 36. Connect negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Chain Guide Plug ................................................................................................................................ ...................................................... 80 Nm (59 ft. lbs.) Timing Fixed Chain Guide Bolt ............................................................................................................................................................ 10 Nm (89 inch lbs.) Timing Upper Chain Guide Bolt ........................................................................................................................................................... 10 Nm (89 inch lbs.) Timing Adjustable Chain Guide Bolt .................................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Camshaft Timing Chain Tensioner ........................................................................................................................................................... 75 Nm (55 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications > Page 2020 Timing Chain Tensioner: Service and Repair "For information regarding this component please refer to timing chain service and repair" Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Front Cover to Block Bolt ..................................................................................................................... ................................................... 25 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2024 Timing Cover: Service and Repair Engine Front Cover Replacement 1. Remove the crankcase balancer. 2. Remove the drive belt tensioner. 3. Remove the engine front cover to water pump bolt. 4. Remove the remaining engine front cover bolts. 5. Remove the engine front cover gasket if it is damaged. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2025 1. If removed install the front cover gasket. 2. Install the engine front cover. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the engine front cover to water pump bolt. ^ Tighten the engine front cover to water pump bolt to 20 Nm (15 ft. lbs.). 4. Install the remaining engine front cover bolts. ^ Tighten the remaining engine front cover bolts to 20 Nm (15 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2026 5. Install the drive belt tensioner. 6. Install the drive belt tensioner bolt. ^ Tighten the drive belt tensioner bolt to 45 Nm (33 ft. lbs.). 7. Install the crankcase balancer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 345-414 kPa (50-60 psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2033 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2034 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Steps 1 - 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2035 Step 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2036 Steps 4 - 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2037 Steps 8 - 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2038 Steps 10 - 12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2039 Steps 13 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2040 Steps 15 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2041 Steps 19 - 21 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the outlet splash shield from the air cleaner. 2. Remove the left headlamp assembly. 3. Remove the upper push-in retainer (1) from the front air cleaner intake duct. 4. Remove the left front tire and wheel. 5. Remove the left front wheel house panel. 6. Remove the lower push-in retainer (4) from the front air cleaner intake duct. 7. Remove the front air cleaner intake duct (3) through the headlamp assembly opening. 8. Remove the resonator rear push-in retainer and the upper attaching bolt (5). 9. Remove the resonator assembly through the wheel house opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2049 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push-in retainer and the upper attaching bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (61 lb in). 3. Install the front air cleaner intake duct (3) through the headlamp assembly opening. 4. Install the lower push-in retainer (4) to the front air cleaner intake duct. 5. Install the left front wheel house panel. 6. Install the left front tire and wheel. 7. Lower the vehicle. 8. Install the upper push-in retainer (1) to the front air cleaner intake duct. 9. Install the headlamp assembly. 10. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2058 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2064 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2065 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the upper air cleaner cover screws to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2072 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2073 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition > Page 2082 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall Spark Plug Misfire Condition > Page 2083 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2089 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2090 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2091 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 20.0 Nm (15.0 lb. ft.) Spark Plug Gap ................................................ ....................................................................................................................................... 1.06 mm (0.042 in.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2092 Spark Plug: Application and ID Spark Plug Type ........................................................................................................................................................ GM P/N 12569190 or AC P/N 41-981 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2093 Spark Plug: Testing and Inspection SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug. SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2094 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2095 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2096 Spark Plug: Service and Repair REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil housing. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. Refer to Spark Plug Inspection. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. GAP Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. IMPORTANT: DO NOT coat the spark plugs with anti seize compound. Over torquing could occur and damage to the cylinder head threads may result. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2097 Tighten Tighten the spark plugs to 20 N.m (15 lb in). 3. Install the ignition coil housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Minimum ........................................................................................................ ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test Tools Required J 35667-A Cylinder Head Leakdown Tester or equivalent Important: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High leakage may indicate one or more of the following: ^ Worn or burnt valves ^ Broken valve springs ^ Stuck valve lifters ^ Incorrect valve lash/adjustment ^ Damaged piston ^ Worn piston rings ^ Worn or scored cylinder bore ^ Damaged cylinder head gasket ^ Cracked or damaged cylinder head ^ Cracked or damaged engine block Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the battery ground negative cable. 2. Remove the spark plugs. 3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke. 4. Install the J 35667-A or equivalent Important: It may be necessary to hold the crankshaft balancer bolt to prevent the engine from rotating. 5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. 6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: ^ Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. ^ Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. ^ Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. ^ Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 7. Perform the leakage test on the remaining cylinders and record the values. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test > Page 2103 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test Perform the following steps in order to conduct a compression test for the L61. 1. Conduct the following steps in order to check cylinder compression. 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ..................................................... 20 Nm (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2110 Water Pump: Service and Repair Water Pump Replacement ^ Tools Required J 43651 Water Pump Holding Tool Removal Procedure 1. If equipped with an automatic transmission, remove the exhaust manifold. 2. Drain the cooling system. 3. Raise and suitably support the vehicle. 4. Remove the right front tire and wheel. 5. Remove the front fender liner. 6. Remove the access plate on the water pump sprocket from the timing cover. 7. Install J 43651 to the water pump sprocket. 8. Use the access plate bolts to secure J 43651 to the engine front cover. 9. Remove the bolts that secure the sprocket to the water pump. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2111 10. Remove the bolt (1) that secures the engine block to the water pump. 11. Remove the bolt (2) that secures the engine front cover to the water pump. 12. Remove the feed pipe that joins the thermostat housing to the water pump. 13. Remove the 2 bolts that secure the water pump to the engine block. 14. Remove the water pump. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2112 1. Use a threaded stud in the hub to align the hub to the water pump sprocket. 2. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 bolts that secure the water pump to the engine block. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the feed pipe that joins the thermostat housing to the water pump. 5. Install the engine front cover bolt (2) and the bolt (1) that secures the engine block to the water pump. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 6. Install 2 of the bolts that secure the water pump sprocket to the water pump. 7. Remove the threaded stud. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2113 8. Install the last bolt. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 9. Remove J 43651. 10. Install the access plate on the water pump sprocket to the timing cover. 11. Install the bolts that secure the access plate to the timing cover. ^ Tighten the bolts to 10 Nm (18 inch lbs.). 12. Install the front fender liner. 13. Install the right front tire and wheel. 14. If equipped with an automatic transmission, install the exhaust manifold. 15. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2119 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2120 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2121 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2122 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .................................................. 8.2 liters (8.6 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2125 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2129 Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Surge Tank Hose/Pipe Replacement Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement Surge Tank Hose/Pipe Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the surge tank pipe clamp (6) from the surge tank outlet hose (5). 3. Remove the surge tank pipe (7) from the surge tank outlet hose (5). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (9) from the surge tank pipe (7). 5. Remove the outlet hose (10) from the surge tank pipe (7). Installation Procedure 1. Install the outlet hose (10) to the surge tank pipe (7) 2. Use the J 38185 in order to reposition the surge tank pipe clamp (9) to the surge tank pipe (7). 3. Install the surge tank pipe (7) to the surge tank outlet hose (5). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (6). 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Surge Tank Hose/Pipe Replacement > Page 2134 Coolant Line/Hose: Service and Repair Surge Tank Hose/Pipe Replacement - Outlet Surge Tank Hose/Pipe Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the surge tank outlet hose clamp (4) from the surge tank outlet hose (5). 3. Remove the surge tank outlet hose (5) from the surge tank. 4. Use the J 38185 in order to reposition the surge tank pipe clamp (6) from the surge tank pipe (7). 5. Remove the surge tank outlet hose (5) from the surge tank pipe (7). Installation Procedure 1. Install the surge tank outlet hose (5) to the surge tank pipe (7). 2. Use the J 38185 in order to reposition the surge tank pipe clamp (6) to the surge tank pipe (7). 3. Install the surge tank outlet hose (5) to the surge tank. 4. Use the J 38185 in order to reposition the surge tank outlet hose clamp (4) to the surge tank outlet hose (5). 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Surge Tank Replacement ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Raise and support the vehicle. 2. Drain the cooling system. 3. Lower the vehicle. 4. Disconnect the low coolant sensor electrical connector. 5. Remove the low coolant sensor electrical harness from the retainer. 6. Use the J 38185 in order to reposition the surge tank outlet hose clamp from the surge tank. 7. Remove the surge tank outlet hose from the surge tank (2). 8. Use the J 38185 in order to reposition the engine vent hose clamp from the surge tank. 9. Remove the engine vent hose from the surge tank (4). 10. Use the J 38185 in order to reposition the radiator vent hose clamp from the surge tank. 11. Remove the radiator vent hose from the surge tank (3). 12. Remove the radiator surge tank mounting bolt. 13. Remove the surge tank. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Page 2138 1. Install the surge tank. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the surge tank mounting bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 3. Install the radiator vent hose to the surge tank (3). 4. Use the J 38185 in order to reposition the radiator vent hose clamp to the surge tank. 5. Install the engine vent hose to the surge tank (4). 6. Use the J 38185 in order to reposition the engine vent hose clamp to the surge tank. 7. Install the surge tank outlet hose to the surge tank (2). 8. Use the J 38185 in order to reposition the surge tank outlet hose clamp to the surge tank. 9. Install the low coolant sensor electrical connector to the retainer. 10. Connect the low coolant electrical connector. 11. Fill the cooling system at the radiator surge tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair Radiator Cooling Fan Motor: Service and Repair Cooling Fan Replacement- Electric Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the hood close out filler retainers. 3. Remove the hood close out filler panel. 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. 4. Disable the air bag sensor. 5. Remove the upper radiator mount bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Page 2143 6. Remove the upper 2 hood latch support bolts (2). 7. Remove the 2 lower hood latch support bolts (4). 8. Raise the vehicle. 9. Remove the cooling fan mounting bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Page 2144 10. Disconnect the electrical connector from the cooling fan. 11. Remove the cooling fan assembly. Installation Procedure 1. Install the cooling fan assembly. 2. Connect the electrical connector to the cooling fan. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the cooling fan mounting bolt. ^ Tighten the bolt to 6 Nm (53 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Page 2145 4. Lower the vehicle. 5. Install the lower 2 hood latch support bolts (4). ^ Tighten the bolts (4) to 27 Nm (20 ft. lbs.). 6. Install the 2 upper hood latch support bolts (2). ^ Tighten the bolts (2) to 9 Nm (80 inch lbs.). 7. Install the upper radiator mount bolts. ^ Tighten bolts to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Service and Repair > Page 2146 8. Engage the air bag sensor. 9. Install the hood close out filler panel. 10. Install the hood close out filler panel retainers. 11. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay. Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay. 2. Install the underhood electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2154 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2155 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2156 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2161 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2162 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2163 Heater Core: Service and Repair HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair 2. Remove the heat stakes and the screws from the heater cover case. 3. Remove the heater cover case. 4. Remove the heater core from the HVAC module assembly. INSTALLATION PROCEDURE 1. Install the heater core to the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2164 2. Install the heater core cover case. 3. Install the heater core cover case screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1 N.m (9 lb in). 4. Install the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the inlet heater hose (1) from the inlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the inlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the inlet heater hose (2) to the inlet port of the heater core. 2. Lower the vehicle. 3. Connect the inlet heater hose to the inlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) > Page 2169 Heater Hose: Service and Repair Heater Hose Replacement - Outlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the outlet heater hose (2) from the outlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the outlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the outlet heater hose (1) to the outlet port of the heater core. 2. Lower the vehicle. 3. Connect the outlet heater hose to the outlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. 2. Turn the drain cock counterclockwise in order to open the drain cock. 3. Pull the stem out of the radiator body. 4. Clean or replace the seal and stem as necessary. Installation Procedure 1. Return the stem to the radiator body. 2. Turn the drain clockwise in order to close the drain cock. 3. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing ^ Tools Required J 24460-01 Cooling System Pressure Tester - J 42401 Radiator Cap/Surge Tank Test Adapter Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure can sealing surface with water. 3. Use J 24460-01 and J 42401 in order to test the pressure cap. 4. Test the pressure cap for the following conditions: ^ Pressure release when J 24460-01 exceeds the pressure rating of the pressure cap. ^ Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap if either of the following conditions is true: ^ The pressure cap does not release pressure which exceeds the rated pressure of the cap. ^ The pressure cap does not hold the rated pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the inlet hose clamp (3) from the water outlet. 3. Remove the inlet radiator hose (2) from the water outlet. 4. Use the J 38185 in order to reposition the inlet hose clamp (1) to the radiator. 5. Remove the inlet radiator hose (2) from the radiator. Installation Procedure 1. Install the inlet radiator hose (2) to the radiator. 2. Use the J 38185 in order to reposition the inlet radiator hose clamp (1) to the radiator. 3. Install the inlet radiator hose (2) to the water outlet. 4. Use the J38185 in order to reposition the inlet radiator hose clamp (3) to the water outlet. 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2181 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet ^ Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Use the J 38185 in order to reposition the outlet hose clamp (8) from the cylinder head. 3. Remove the outlet hose from the cylinder head (10). 4. Raise and suitably support the vehicle. 5. Use the J 38185 in order to reposition the surge tank pipe clamp (9). 6. Remove the outlet hose (10) from the surge tank pipe (7). 7. Use the J 38185 in order to reposition the outlet hose clamp (11) from the radiator. 8. Remove the outlet hose (10) from the radiator. Installation Procedure 1. Install the outlet hose (10) to the radiator. 2. Use the J 38185 in order to reposition the outlet hose clamp (11) to the radiator. 3. Install the outlet hose (10) to the surge tank pipe (7). 4. Use the J 38185 in order to reposition the surge tank pipe clamp (9). 5. Lower the vehicle. 6. Install the outlet hose to the cylinder head (10). 7. Use the J 38185 in order to position the outlet hose clamp (8) to the cylinder head. 8. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Service and Repair Radiator Cooling Fan Motor Relay: Service and Repair Cooling Fan Relay Replacement ^ Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the underhood electrical center cover. 2. Using the J 43244, remove the cooling fan relay. Installation Procedure Notice: Installation of the proper relay is critical. If an enhanced relay-equipped with a diode-is installed into a position requiring a standard relay- equipped without a diode-excessive current will damage any components associated with the relay or its associated circuits. 1. Install the cooling fan relay. 2. Install the underhood electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations > Page 2190 Coolant Level Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2195 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2196 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2197 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat opening temperature ........................................................................................................ .............................................................. 82°C (180°F) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2201 Thermostat: Service and Repair Thermostat Replacement Removal Procedure 1. If equipped with an automatic transmission, remove the exhaust manifold. 2. Drain the cooling system. 3. Remove the thermostat housing to water pump feed pipe bolts. 4. Remove the thermostat housing to water pump feed pipe. 5. Remove the thermostat. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2202 Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing to water pump feed pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the thermostat housing to water pump feed pipe bolt. ^ Tighten the thermostat housing to water pump feed pipe bolt to 10 Nm (18 inch lbs.). 4. If equipped with an automatic transmission, install the exhaust manifold. 5. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ..................................................... 20 Nm (15 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2206 Water Pump: Service and Repair Water Pump Replacement ^ Tools Required J 43651 Water Pump Holding Tool Removal Procedure 1. If equipped with an automatic transmission, remove the exhaust manifold. 2. Drain the cooling system. 3. Raise and suitably support the vehicle. 4. Remove the right front tire and wheel. 5. Remove the front fender liner. 6. Remove the access plate on the water pump sprocket from the timing cover. 7. Install J 43651 to the water pump sprocket. 8. Use the access plate bolts to secure J 43651 to the engine front cover. 9. Remove the bolts that secure the sprocket to the water pump. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2207 10. Remove the bolt (1) that secures the engine block to the water pump. 11. Remove the bolt (2) that secures the engine front cover to the water pump. 12. Remove the feed pipe that joins the thermostat housing to the water pump. 13. Remove the 2 bolts that secure the water pump to the engine block. 14. Remove the water pump. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2208 1. Use a threaded stud in the hub to align the hub to the water pump sprocket. 2. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 2 bolts that secure the water pump to the engine block. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the feed pipe that joins the thermostat housing to the water pump. 5. Install the engine front cover bolt (2) and the bolt (1) that secures the engine block to the water pump. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 6. Install 2 of the bolts that secure the water pump sprocket to the water pump. 7. Remove the threaded stud. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2209 8. Install the last bolt. ^ Tighten the bolts to 10 Nm (89 inch lbs.). 9. Remove J 43651. 10. Install the access plate on the water pump sprocket to the timing cover. 11. Install the bolts that secure the access plate to the timing cover. ^ Tighten the bolts to 10 Nm (18 inch lbs.). 12. Install the front fender liner. 13. Install the right front tire and wheel. 14. If equipped with an automatic transmission, install the exhaust manifold. 15. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2215 Catalytic Converter: Service and Repair Catalytic Converter Replacement Removal Procedure Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the three way catalytic converter. 3. Remove the intermediate pipe bolts. 4. Remove the exhaust manifold bolts. 5. Remove the three way catalytic converter bracket bolt. 6. Remove the three way catalytic converter and seals. 7. Clean the flange surfaces. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2216 1. Install the three way catalytic converter seals. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the intermediate pipe bolts. ^ Tighten the intermediate pipe bolts to 30 Nm (22 ft. lbs.). 3. Install the three way catalytic converter to the exhaust manifold. ^ Tighten the exhaust manifold pipe bolts to 45 Nm (33 ft. lbs.). 4. Install three-way catalytic converter bracket bolt. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold to Cylinder Head Nut .................................................................................................................................................... 12 Nm (9 ft. lbs.) Exhaust Manifold to Cylinder Head Stud .............................................................................................................................................. 10 Nm (89 inch lbs.) Exhaust Manifold Pipe Flange Stud ......................................................................................................................................................... 16 Nm (12 ft. lbs.) Heat Shield to Exhaust Manifold Bolt ................................................................................................................................................... 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2220 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the exhaust manifold heat shield. 3. Remove the oxygen sensor. 4. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Do not bend the exhaust fox decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2221 5. Remove the pipe to manifold nuts (3). 6. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold. 7. Lower the vehicle. 8. Remove the exhaust manifold to cylinder head nuts. 9. Remove the exhaust manifold. 10. Clean all the sealing surfaces. Installation Procedure 1. Install a new exhaust manifold gasket. 2. Install the exhaust manifold to the cylinder head. Notice: Refer to Fastener Notice in Service Precautions. Important: Install the new exhaust nuts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2222 3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence. ^ Tighten the nuts to 18 Nm (12 ft. lbs.). 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Install a new exhaust manifold to flex coupler gasket (2). 6. Push the flex coupler into position on the exhaust manifold. Important: Install the new exhaust nuts. 7. Install the retaining nuts (3) which secure the manifold to the flex decoupler (4). ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 8. Lower the vehicle. 9. Install the oxygen sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2223 10. Install the exhaust manifold heat shield. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 11. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications Exhaust Pipe: Specifications Exhaust Manifold Pipe Bolt .................................................................................................................. .................................................... 45 Nm (33 ft. lbs.) Intermediate Pipe Bolt ....................................... ....................................................................................................................................... 30 Nm (22 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2227 Exhaust Pipe: Service and Repair Intermediate Pipe Replacement Removal Procedure Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. Important: A service muffler will be needed when replacing the intermediate pipe on an originally equipped, welded system. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the three way catalytic converter. 3. Cut the intermediate pipe (1) at the muffler (2). 4. Remove the intermediate pipe bolts at catalytic converter. 5. Remove the intermediate pipe from the hanger. 6. Remove the intermediate pipe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2228 7. Remove the three way catalytic converter seals. 8. Clean the flange surface. Installation Procedure 1. Install the three way catalytic converter seals. 2. Install the intermediate pipe to the hanger. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Specifications > Page 2229 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the intermediate pipe bolts to catalytic converter. ^ Tighten the intermediate pipe bolts to 30 Nm (22 ft. lbs.). 4. Weld the muffler (2) to the intermediate pipe (1). 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler Hanger Bolt .............................................................................................................................. ................................................... 16 Nm (12 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2233 Muffler: Service and Repair Muffler Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Cut the intermediate pipe (1) at the muffler (2) near the weld. 3. Remove the muffler hanger bolts. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the muffler hanger bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 2234 ^ Tighten the muffler hanger bolts to 16 Nm (12 ft. lbs.). 2. Clamp the muffler to the intermediate pipe. 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) Body Control Module: Description and Operation Body Control Module (BCM) BODY CONTROL MODULE The various BCM input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The Body Control Module functions include the following. - Retained Accessory Power, RAP, Audio System only. - A/C compressor request. - Remote Function Control. - A/C cooling Fan. - Exterior and interior lighting control Daytime running lights (DRL) - Automatic lighting control - Fog lamps - Interior lighting. - Battery rundown protection (Inadvertent Power). - Chimes. Key In Ignition - Head Lamps On - Seat Belt Not Fastened - Turn Signal On - Park Brake Warning - Door Ajar Warning - Check gauges - Gauge control. - Instrument cluster indicator control. - Theft deterrent. - Engine coolant level sensing. - Key-in-ignition sensing. - Brake fluid level sensing. - Parking brake state sensing. - Rear compartment interface. - Horn interface. - Door lock interface. - Bulb Check. - ETS -Pontiac Only. - A/T Shift lock control. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2243 Body Control Module: Description and Operation Content Theft Deterrent (CTD) CONTENT THEFT DETERRENT (CTD) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2244 Body Control Module: Description and Operation Vehicle Theft Deterrent (VTD) CONTENT THEFT DETERRENT (CTD) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. The body control module (BCM) must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the SPECIAL FUNCTIONS menu on the scan tool to program the BCM. Select NEW BCM SETUP and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passlock Learn Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passlock Learn procedure. Perform the Learn Procedure if any of the following components have been replaced: The body control module (BCM) - The Passlock sensor - The powertrain control module (PCM) IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2247 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Release the body control module (BCM) wire harness retainer from the BCM bracket. 3. Disconnect the BCM electrical connectors from the BCM. 4. Release the lock tabs and remove the BCM from the BCM bracket. 5. Remove the BCM bracket nuts (2) if required. 6. Remove the BCM bracket (1) as an assembly if required. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2248 1. Install the BCM bracket (1) as an assembly if required. 2. Install the BCM bracket nuts (2) if required. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Install the BCM into the BCM bracket until lock tabs are fully seated. 4. Connect the BCM electrical connectors to the BCM. 5. Install the BCM wire harness retainer to the BCM bracket. 6. Connect the negative battery cable. 7. Reprogram the BCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2253 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2254 Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2255 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2256 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2257 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description & Function POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function > Page 2260 Engine Control Module: Description and Operation Powertrain Control Module (PCM)/Theft Deterrent Control Module POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2261 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first in order to verify the PCM is the correct part. DTC P0602 indicates the EEPROM programming has malfunctioned. When DTC P0602 is set, re-program the EEPROM. 1. Disconnect the negative battery cable. 2. Push down the locking tab and pull up on the release lever and disconnect the PCM harness connectors (1). NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Press the PCM retaining tab. 4. Lift the PCM (2) from the PCM bracket (3). INSTALLATION PROCEDURE Remove the new PCM from the packaging and inspect the service number to verify the number is the same number, or an updated number, as the faulty PCM. 1. Push the PCM (2) into the PCM bracket (3). The retaining tab will lock in place. 2. Install the PCM harness connectors (1) and lock down the release levers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2262 NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning IMPORTANT: The replacement PCM must be reprogrammed and the crankshaft position system variation learn procedure must be performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2267 Ignition Control Module (ICM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2268 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS 1. Ignition Control Module (ICM) 2. Compression Sense Ignition (CSI) Pickup 3. Not Used 4. 2-3 Coil Control 5. Ignition Voltage 6. 1-4 Coil Control 7. Not Used 8. Interconnect Each ignition coil is responsible for supplying secondary energy to a pair of spark plugs. The ignition control signals output by the PCM are amplified by the ICM in order to fire each coil. The spark events are triggered by the ICM, but the module has no influence on spark timing. The ICM is also responsible for detecting and supplying a camshaft position (CMP) signal pulse to the PCM to be used for sequential fuel injection. This ignition system does not use a conventional CMP sensor that detects valve train position. The ICM detects when either cylinder 1 or cylinder 3 has fired on the cylinders compression stroke using sensing circuitry integrated within each coil. The sensing circuit detects the polarity and the strength of the secondary voltage output, the higher output is always at the event cylinder. The ICM sends a CMP signal to the PCM based on the voltage difference between the event and waste cylinder firing energy. This system is called compression sense ignition. By monitoring the camshaft position and crankshaft position (CKP) signals the PCM can accurately time the operation of the fuel injectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2269 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the accelerator cable from the bracket. 3. Remove the accelerator cable bracket bolt. 4. Remove the accelerator cable bracket. 5. Disconnect the ignition control module (ICM) harness connector. 6. Remove the ICM retaining screws. 7. Remove the ICM from the ignition coil housing. INSTALLATION PROCEDURE 1. Install the ignition control module in the ignition coil housing. IMPORTANT: Make sure the interconnect and seal are lined up before module installation. 2. Install the ICM retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 1.5 N.m (13 lb in). 3. Connect the ICM harness connector. 4. Install the accelerator cable bracket. 5. Install the accelerator cable bracket bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2270 NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 10 N.m (18 lb in). 6. Install the accelerator cable to the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2276 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch Clutch Pedal Position (CPP) Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2277 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Remove the electrical connector from the clutch pedal position switch. 2. Remove the clutch pedal position switch from the brake and accelerator and clutch pedal with the bracket. Installation Procedure 1. Install the clutch pedal position switch to the brake and accelerator and clutch pedal with the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2278 2. Install the electrical connector to the clutch pedal position switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2282 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2283 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2284 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2288 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2289 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2290 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2293 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2294 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2298 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2299 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2300 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2304 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2305 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2306 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel tank pressure (FTP) sensor connector. 3. Remove the FTP sensor from the fuel sender. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2307 1. Install the FTP sensor to the fuel sender. 2. Connect the FTP sensor connector. 3. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2311 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2312 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the air cleaner duct from the air cleaner resonator. 2. Disconnect the IAT sensor harness connector. 3. While twisting the IAT sensor (4), pull the sensor from the air cleaner resonator (1). INSTALLATION PROCEDURE 1. Press the IAT sensor (4) into the air cleaner resonator (1). 2. Connect the IAT sensor harness connector. 3. Connect the air cleaner duct to the air cleaner resonator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2316 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2317 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2318 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2322 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2323 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the accelerator cable bracket. 3. Disconnect the manifold absolute pressure (MAP) sensor harness connector. 4. Remove the MAP sensor (2) from the intake manifold. 5. Inspect the seal for damage. IMPORTANT: If the MAP sensor seal is damaged, the MAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the MAP sensor (2) into the intake manifold. IMPORTANT: Use the new MAP sensor seal provided with the new MAP sensor. 2. Connect the MAP sensor harness connector. 3. Install the accelerator cable bracket. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2327 Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2328 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter Oxygen Sensor: Service and Repair Pre Catalytic Converter REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2331 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2332 Oxygen Sensor: Service and Repair Post Catalytic Converter REMOVAL PROCEDURE NOTE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. - Take care when handling the rear heated oxygen sensor (HO2S 2). The in-line connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn OFF the ignition. 2. Disconnect the HO2S 2 connector, in the Engine Compartment. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Carefully remove the HO2S 2. NOTE: The use of excessive force may damage the threads in the exhaust manifold/pipe. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. Coat the threads only of the HO2S 2 with anti-seize compound, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2333 2. Install the HO2S 2. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the HO2S 2 to 41 N.m (30 lb ft). 3. Lower the vehicle. 4. Reconnect the HO2S 2 connector, in the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2337 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2338 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2342 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2343 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2351 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2352 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2357 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2358 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2359 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2362 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2363 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2367 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2368 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2369 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 345-414 kPa (50-60 psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2376 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2377 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Steps 1 - 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2378 Step 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2379 Steps 4 - 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2380 Steps 8 - 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2381 Steps 10 - 12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2382 Steps 13 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2383 Steps 15 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2384 Steps 19 - 21 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the outlet splash shield from the air cleaner. 2. Remove the left headlamp assembly. 3. Remove the upper push-in retainer (1) from the front air cleaner intake duct. 4. Remove the left front tire and wheel. 5. Remove the left front wheel house panel. 6. Remove the lower push-in retainer (4) from the front air cleaner intake duct. 7. Remove the front air cleaner intake duct (3) through the headlamp assembly opening. 8. Remove the resonator rear push-in retainer and the upper attaching bolt (5). 9. Remove the resonator assembly through the wheel house opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2392 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push-in retainer and the upper attaching bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (61 lb in). 3. Install the front air cleaner intake duct (3) through the headlamp assembly opening. 4. Install the lower push-in retainer (4) to the front air cleaner intake duct. 5. Install the left front wheel house panel. 6. Install the left front tire and wheel. 7. Lower the vehicle. 8. Install the upper push-in retainer (1) to the front air cleaner intake duct. 9. Install the headlamp assembly. 10. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2401 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2407 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2408 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the upper air cleaner cover screws to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2415 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2416 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2425 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2426 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2432 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 2433 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2434 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 20.0 Nm (15.0 lb. ft.) Spark Plug Gap ................................................ ....................................................................................................................................... 1.06 mm (0.042 in.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2435 Spark Plug: Application and ID Spark Plug Type ........................................................................................................................................................ GM P/N 12569190 or AC P/N 41-981 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2436 Spark Plug: Testing and Inspection SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug. SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2437 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2438 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2439 Spark Plug: Service and Repair REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil housing. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. Refer to Spark Plug Inspection. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. GAP Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. IMPORTANT: DO NOT coat the spark plugs with anti seize compound. Over torquing could occur and damage to the cylinder head threads may result. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 2440 Tighten Tighten the spark plugs to 20 N.m (15 lb in). 3. Install the ignition coil housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Minimum ........................................................................................................ ....................................................... 689 kPa (100 psi) The lowest reading cylinder should not be less than 70 percent of the highest Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test Compression Check: Testing and Inspection Cylinder Leakage Test Cylinder Leakage Test Tools Required J 35667-A Cylinder Head Leakdown Tester or equivalent Important: A leakage test may be performed in order to measure cylinder/combustion chamber leakage. High leakage may indicate one or more of the following: ^ Worn or burnt valves ^ Broken valve springs ^ Stuck valve lifters ^ Incorrect valve lash/adjustment ^ Damaged piston ^ Worn piston rings ^ Worn or scored cylinder bore ^ Damaged cylinder head gasket ^ Cracked or damaged cylinder head ^ Cracked or damaged engine block Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the battery ground negative cable. 2. Remove the spark plugs. 3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke. 4. Install the J 35667-A or equivalent Important: It may be necessary to hold the crankshaft balancer bolt to prevent the engine from rotating. 5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. 6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: ^ Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. ^ Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. ^ Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. ^ Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. 7. Perform the leakage test on the remaining cylinders and record the values. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis > Cylinder Leakage Test > Page 2446 Compression Check: Testing and Inspection Engine Compression Test Engine Compression Test Perform the following steps in order to conduct a compression test for the L61. 1. Conduct the following steps in order to check cylinder compression. 1.1. Engine should be at room temperature. 1.2. Disconnect wiring from the ignition module 1.3. Remove the spark plugs. 1.4. Throttle body valve should be wide open. 1.5. Battery should be at or near full charge. 2. For each cylinder, crank engine through four compression strokes. 3. The lowest reading cylinder should not be less than 70 percent of the highest. 4. No cylinder reading should be less than 689 kPa (100 psi). Important: The results of a compression test will fall into the following categories: ^ Normal Compression builds up quickly and evenly to specified compression on each cylinder. ^ Piston Rings Compression is low on the first stroke, tends to build up on following strokes, but does not reach normal. Compression improves considerably with the addition of oil. ^ Valves Compression is low on the first stroke, does not tend to build up on the following strokes, and does not improve much with the addition of oil. Use approximately three squirts from a plunger-type oiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2454 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2455 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the air cleaner duct from the air cleaner resonator. 2. Disconnect the IAT sensor harness connector. 3. While twisting the IAT sensor (4), pull the sensor from the air cleaner resonator (1). INSTALLATION PROCEDURE 1. Press the IAT sensor (4) into the air cleaner resonator (1). 2. Connect the IAT sensor harness connector. 3. Connect the air cleaner duct to the air cleaner resonator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) Body Control Module: Description and Operation Body Control Module (BCM) BODY CONTROL MODULE The various BCM input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The Body Control Module functions include the following. - Retained Accessory Power, RAP, Audio System only. - A/C compressor request. - Remote Function Control. - A/C cooling Fan. - Exterior and interior lighting control Daytime running lights (DRL) - Automatic lighting control - Fog lamps - Interior lighting. - Battery rundown protection (Inadvertent Power). - Chimes. Key In Ignition - Head Lamps On - Seat Belt Not Fastened - Turn Signal On - Park Brake Warning - Door Ajar Warning - Check gauges - Gauge control. - Instrument cluster indicator control. - Theft deterrent. - Engine coolant level sensing. - Key-in-ignition sensing. - Brake fluid level sensing. - Parking brake state sensing. - Rear compartment interface. - Horn interface. - Door lock interface. - Bulb Check. - ETS -Pontiac Only. - A/T Shift lock control. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2461 Body Control Module: Description and Operation Content Theft Deterrent (CTD) CONTENT THEFT DETERRENT (CTD) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2462 Body Control Module: Description and Operation Vehicle Theft Deterrent (VTD) CONTENT THEFT DETERRENT (CTD) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. The body control module (BCM) must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the SPECIAL FUNCTIONS menu on the scan tool to program the BCM. Select NEW BCM SETUP and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passlock Learn Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passlock Learn procedure. Perform the Learn Procedure if any of the following components have been replaced: The body control module (BCM) - The Passlock sensor - The powertrain control module (PCM) IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2465 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Release the body control module (BCM) wire harness retainer from the BCM bracket. 3. Disconnect the BCM electrical connectors from the BCM. 4. Release the lock tabs and remove the BCM from the BCM bracket. 5. Remove the BCM bracket nuts (2) if required. 6. Remove the BCM bracket (1) as an assembly if required. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2466 1. Install the BCM bracket (1) as an assembly if required. 2. Install the BCM bracket nuts (2) if required. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Install the BCM into the BCM bracket until lock tabs are fully seated. 4. Connect the BCM electrical connectors to the BCM. 5. Install the BCM wire harness retainer to the BCM bracket. 6. Connect the negative battery cable. 7. Reprogram the BCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2470 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch Clutch Pedal Position (CPP) Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2471 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Remove the electrical connector from the clutch pedal position switch. 2. Remove the clutch pedal position switch from the brake and accelerator and clutch pedal with the bracket. Installation Procedure 1. Install the clutch pedal position switch to the brake and accelerator and clutch pedal with the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2472 2. Install the electrical connector to the clutch pedal position switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2476 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2477 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2478 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2482 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2483 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2484 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2487 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2488 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Under The Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2496 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2497 Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2498 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2499 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2500 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description & Function POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function > Page 2503 Engine Control Module: Description and Operation Powertrain Control Module (PCM)/Theft Deterrent Control Module POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2504 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first in order to verify the PCM is the correct part. DTC P0602 indicates the EEPROM programming has malfunctioned. When DTC P0602 is set, re-program the EEPROM. 1. Disconnect the negative battery cable. 2. Push down the locking tab and pull up on the release lever and disconnect the PCM harness connectors (1). NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Press the PCM retaining tab. 4. Lift the PCM (2) from the PCM bracket (3). INSTALLATION PROCEDURE Remove the new PCM from the packaging and inspect the service number to verify the number is the same number, or an updated number, as the faulty PCM. 1. Push the PCM (2) into the PCM bracket (3). The retaining tab will lock in place. 2. Install the PCM harness connectors (1) and lock down the release levers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2505 NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning IMPORTANT: The replacement PCM must be reprogrammed and the crankshaft position system variation learn procedure must be performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2509 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2510 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2511 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2515 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2516 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2517 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel tank pressure (FTP) sensor connector. 3. Remove the FTP sensor from the fuel sender. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2518 1. Install the FTP sensor to the fuel sender. 2. Connect the FTP sensor connector. 3. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2522 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts 10 allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2523 Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2524 Steps 7-11 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2525 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2526 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the idle air control (IAC) valve harness connector (1). 3. Remove the IAC valve screw. 4. Remove the IAC valve and seal. Cleaning and Inspection Procedure If using the original IAC valve, perform the following inspection and cleaning procedure: Clean the IAC valve sealing surface, pintle valve seat and air passage in the throttle body. - Whenever the air passages have heavy deposits, remove the throttle body for a complete cleaning. - The IAC valve may be cleaned by using a shop towel or small parts cleaning brush to remove heavy deposits. - Shiny spots on the pintle or seat are normal, and not an indication of a misaligned pintle shaft. - Inspect the IAC valve seal for cuts, cracks or distortion. Replace the IAC valve if the seal is damaged. - Whenever installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are specific to this application. - Compare the distance between the tip, or the pintle, and the mounting flange of the new and old IAC valves. Use finger pressure to slowly retract the pintle of the new valve to the distance of the old. This will not cause damage to the new IAC valve but is critical for installation. INSTALLATION PROCEDURE 1. Lubricate the IAC valve seal with clean engine oil. 2. Install the IAC valve into the throttle body. 3. Install the IAC valve screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new screw when replacing the IAC valve. Tighten Tighten the IAC valve screw to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 2527 4. Connect the IAC valve harness connector (1). 5. Install the air cleaner outlet resonator. 6. Reset the IAC valve pintle using the following procedure: 6.1. Turn ON the ignition, with the engine OFF. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Start the engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Connector Views Data Link Connector Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Connector Views > Page 2532 Information Bus: Electrical Diagrams Data Link Connector (DLC) Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2533 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION DATA LINK CONNECTOR (DLC) The data link connector (DLC) terminal 2 contains the class 2 serial data link. The DLC also provides a power source and Signal Ground for the scan tool as follows: Battery voltage at the DLC terminal 16 (circuit 40) - Power Ground at terminal 4 (circuit 150) - Signal Ground at terminal 5 (circuit 451) CLASS 2 SERIAL DATA LINK The class 2 serial data link allows the following modules to communicate with each other: The body control module (BCM) - Digital radio receiver (DRR) - The electronic brake control module (EBCM) - The instrument panel cluster (IPC) - The radio. - The powertrain control module (PCM) - The inflatable restraint sensing and diagnostic module (SDM) - Vehicle communication interface module (VCIM) The class 2 serial data link allows a scan tool to communicate with the above modules for diagnostic and testing purposes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the data link communications system by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2536 Information Bus: Symptom Related Diagnostic Procedures Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. DIAGNOSTIC AIDS - The engine will not start when there is a total malfunction of the Class 2 serial data circuit while the engine is not running. - The power mode master must be able to communicate over the Class 2 serial data bus in order for the Tech 2 to communicate with the other modules. - The PCM on this vehicle has 3 junctions to the Class 2 serial data bus. TEST DESCRIPTION Steps 1 - 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2537 Steps 5 - 8 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2538 Steps 9 - 10 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2539 Step 11 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2540 Steps 12 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2541 Steps 15 - 16 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2542 Steps 17 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2543 Step 19 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2544 Step 20 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2545 Steps 21 - 22 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2546 Step 23 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2547 Step 24 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2548 Step 25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2549 Steps 26 - 28 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2550 Steps 29 - 33 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2551 Steps 34 - 37 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2552 Steps 38 - 40 The numbers below refer to the step numbers on the diagnostic table . 2. A partial malfunction in the Class 2 serial data circuit uses a different procedure from a total malfunction of the Class 2 serial data circuit. 3. The DTC U1300 and U1301 may be retrieved with a history status. These DTCs are not the cause of the present condition. 6. A State of Health DTC with a history status may be present along with a U1000 with a current status. This indicates that the malfunction occurred when the ignition was on. 7. Data link connector terminals 2 and 5 provide the connection to the Class 2 serial data circuit and the signal ground circuit respectively. 10. An open in the Class 2 serial data circuit between the DLC and the body control module (BCM) will prevent the scan tool from communicating with any module. This condition will not set a DTC. 11. If communication can be established, the malfunction is not in the BCM or the wiring from the DLC to the BCM. 12. This test attempts to establish communication with the Radio. 13. This test attempts to establish communication with the DRR. 14. This test attempts to establish communication with the VCIM. 15. This test attempts to establish communication with the PCM. 16. This test attempts to establish communication with the IPC. 17. This test attempts to establish communication with the SDM. 18. This test attempts to establish communication with the EBCM. 19. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the BCM. 20. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the Radio. 21. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit between the Radio and the DRR module. 22. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit between the Radio and the VCIM module. 23. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the PCM. 24. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the IPC. 25. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the SDM. 26. This test analyzes the condition of the wiring and connectors in the Class 2 serial data circuit of the EBCM. 36. If there are no current DTCs that begin with a U, the communication malfunction has been repaired. 38. The interruption of the Class 2 serial data circuit may have prevented the diagnosis of the customer complaint. Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) provides operating power for the scan tool at terminal 16 (battery positive voltage) and at terminal 4 (ground). The DLC provides the class 2 serial data signal at terminal 2 and signal ground at terminal 5. The scan tool will power up with the ignition off. Many modules, however, will not communicate unless the ignition is on. TEST DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2553 Step 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2554 Steps 2 - 4 The numbers below refer to the step numbers on the diagnostic table. 1. The CIG fuse supplies power to terminal 16 of the DLC. 4. The battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2558 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2559 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2560 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned "ON", with the engine "OFF". This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns "OFF" after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns "OFF" after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is "ON". * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled "OFF" and then "ON". SERVICE VEHICLE SOON The instrument panel cluster (IPC) illuminates the service vehicle soon indicator during any of the following conditions: * The body control module (BCM) detects a PASSLOCK failure. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a malfunction in the passive trunk release system. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a failure in the traction control system. The BCM sends a class 2 message to the IPC requesting illumination. * The IPC detects a mismatch between its part number and the vehicle platform configuration sent by the BCM via a class 2 message. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 2564 Malfunction Indicator Lamp: Service and Repair CHECK ENGINE OR SERVICE ENGINE SOON The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2568 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2569 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the accelerator cable bracket. 3. Disconnect the manifold absolute pressure (MAP) sensor harness connector. 4. Remove the MAP sensor (2) from the intake manifold. 5. Inspect the seal for damage. IMPORTANT: If the MAP sensor seal is damaged, the MAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the MAP sensor (2) into the intake manifold. IMPORTANT: Use the new MAP sensor seal provided with the new MAP sensor. 2. Connect the MAP sensor harness connector. 3. Install the accelerator cable bracket. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2573 Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2574 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter Oxygen Sensor: Service and Repair Pre Catalytic Converter REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2577 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2578 Oxygen Sensor: Service and Repair Post Catalytic Converter REMOVAL PROCEDURE NOTE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. - Take care when handling the rear heated oxygen sensor (HO2S 2). The in-line connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn OFF the ignition. 2. Disconnect the HO2S 2 connector, in the Engine Compartment. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Carefully remove the HO2S 2. NOTE: The use of excessive force may damage the threads in the exhaust manifold/pipe. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. Coat the threads only of the HO2S 2 with anti-seize compound, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2579 2. Install the HO2S 2. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the HO2S 2 to 41 N.m (30 lb ft). 3. Lower the vehicle. 4. Reconnect the HO2S 2 connector, in the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) Body Control Module: Description and Operation Body Control Module (BCM) BODY CONTROL MODULE The various BCM input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The Body Control Module functions include the following. - Retained Accessory Power, RAP, Audio System only. - A/C compressor request. - Remote Function Control. - A/C cooling Fan. - Exterior and interior lighting control Daytime running lights (DRL) - Automatic lighting control - Fog lamps - Interior lighting. - Battery rundown protection (Inadvertent Power). - Chimes. Key In Ignition - Head Lamps On - Seat Belt Not Fastened - Turn Signal On - Park Brake Warning - Door Ajar Warning - Check gauges - Gauge control. - Instrument cluster indicator control. - Theft deterrent. - Engine coolant level sensing. - Key-in-ignition sensing. - Brake fluid level sensing. - Parking brake state sensing. - Rear compartment interface. - Horn interface. - Door lock interface. - Bulb Check. - ETS -Pontiac Only. - A/T Shift lock control. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2586 Body Control Module: Description and Operation Content Theft Deterrent (CTD) CONTENT THEFT DETERRENT (CTD) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 2587 Body Control Module: Description and Operation Vehicle Theft Deterrent (VTD) CONTENT THEFT DETERRENT (CTD) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. The body control module (BCM) must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the SPECIAL FUNCTIONS menu on the scan tool to program the BCM. Select NEW BCM SETUP and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passlock Learn Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passlock Learn procedure. Perform the Learn Procedure if any of the following components have been replaced: The body control module (BCM) - The Passlock sensor - The powertrain control module (PCM) IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2590 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Release the body control module (BCM) wire harness retainer from the BCM bracket. 3. Disconnect the BCM electrical connectors from the BCM. 4. Release the lock tabs and remove the BCM from the BCM bracket. 5. Remove the BCM bracket nuts (2) if required. 6. Remove the BCM bracket (1) as an assembly if required. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2591 1. Install the BCM bracket (1) as an assembly if required. 2. Install the BCM bracket nuts (2) if required. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Install the BCM into the BCM bracket until lock tabs are fully seated. 4. Connect the BCM electrical connectors to the BCM. 5. Install the BCM wire harness retainer to the BCM bracket. 6. Connect the negative battery cable. 7. Reprogram the BCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2596 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2597 Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2598 Engine Control Module: Diagrams Powertrain Control Module (PCM) C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2599 Powertrain Control Module (PCM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2600 Powertrain Control Module (PCM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function Engine Control Module: Description and Operation Powertrain Control Module (PCM) Description & Function POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module (PCM) Description & Function > Page 2603 Engine Control Module: Description and Operation Powertrain Control Module (PCM)/Theft Deterrent Control Module POWERTRAIN CONTROL MODULE The powertrain control module (PCM) contains the remainder of the logic of the theft deterrent system. If a class 2 message containing a valid password is received from the BCM, the PCM will continue to allow the fuel injectors to operate. The PCM will allow the fuel injectors to operate until it decides there is no valid password coming from the BCM. If the PCM does not receive a class 2 message, or receives a class 2 message with an incorrect password, the engine will crank and will not run or will start and stall immediately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2604 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT REMOVAL PROCEDURE NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector. Service should normally consist of either replacement of the PCM or EEPROM re-programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be inspected first in order to verify the PCM is the correct part. DTC P0602 indicates the EEPROM programming has malfunctioned. When DTC P0602 is set, re-program the EEPROM. 1. Disconnect the negative battery cable. 2. Push down the locking tab and pull up on the release lever and disconnect the PCM harness connectors (1). NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Press the PCM retaining tab. 4. Lift the PCM (2) from the PCM bracket (3). INSTALLATION PROCEDURE Remove the new PCM from the packaging and inspect the service number to verify the number is the same number, or an updated number, as the faulty PCM. 1. Push the PCM (2) into the PCM bracket (3). The retaining tab will lock in place. 2. Install the PCM harness connectors (1) and lock down the release levers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2605 NOTE: Do not touch the PCM connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage. Do not remove the integrated circuit boards from the carrier. 3. Connect the negative battery cable. 4. Program the PCM. See: Testing and Inspection/Programming and Relearning IMPORTANT: The replacement PCM must be reprogrammed and the crankshaft position system variation learn procedure must be performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations Clutch Pedal Position Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2610 Clutch Switch: Diagrams Clutch Pedal Position (CPP) Switch Clutch Pedal Position (CPP) Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2611 Clutch Switch: Service and Repair Clutch Pedal Position Switch Replacement Removal Procedure 1. Remove the electrical connector from the clutch pedal position switch. 2. Remove the clutch pedal position switch from the brake and accelerator and clutch pedal with the bracket. Installation Procedure 1. Install the clutch pedal position switch to the brake and accelerator and clutch pedal with the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Locations > Page 2612 2. Install the electrical connector to the clutch pedal position switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2616 Engine Coolant Temperature (ECT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2617 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Turn OFF the ignition. 2. Drain the coolant system to below the ECT sensor. Refer to Draining and Filling Cooling System (L61) in Cooling System. 3. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 4. Carefully remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. - Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If you are reinstalling the original sensor, or if you are installing a new sensor without a sealer, coat the threads with sealer P/N 9985253 or an equivalent. 2. Install the ECT sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2618 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the ECT sensor to 10 N.m (89 lb in). 3. Connect the ECT sensor electrical connector. 4. Refill the engine coolant system. Refer to Draining and Filling Cooling System (L61) in Cooling System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2622 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2623 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2624 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2627 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2628 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2632 Fuel Level Sensor: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2633 Fuel Level Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2634 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2638 Fuel Tank Pressure (FTP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2639 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2640 Fuel Tank Pressure Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the fuel tank pressure (FTP) sensor connector. 3. Remove the FTP sensor from the fuel sender. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2641 1. Install the FTP sensor to the fuel sender. 2. Connect the FTP sensor connector. 3. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2645 Intake Air Temperature (IAT) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations > Page 2646 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the air cleaner duct from the air cleaner resonator. 2. Disconnect the IAT sensor harness connector. 3. While twisting the IAT sensor (4), pull the sensor from the air cleaner resonator (1). INSTALLATION PROCEDURE 1. Press the IAT sensor (4) into the air cleaner resonator (1). 2. Connect the IAT sensor harness connector. 3. Connect the air cleaner duct to the air cleaner resonator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2650 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2651 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2652 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2656 Manifold Absolute Pressure (MAP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2657 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Remove the accelerator cable bracket. 3. Disconnect the manifold absolute pressure (MAP) sensor harness connector. 4. Remove the MAP sensor (2) from the intake manifold. 5. Inspect the seal for damage. IMPORTANT: If the MAP sensor seal is damaged, the MAP sensor must be replaced. INSTALLATION PROCEDURE 1. Install the MAP sensor (2) into the intake manifold. IMPORTANT: Use the new MAP sensor seal provided with the new MAP sensor. 2. Connect the MAP sensor harness connector. 3. Install the accelerator cable bracket. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2661 Rear Of Engine Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2662 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter Oxygen Sensor: Service and Repair Pre Catalytic Converter REMOVAL PROCEDURE NOTE: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. - The use of excessive force may damage the threads in the exhaust manifold/pipe. IMPORTANT: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the oxygen sensor. - The oxygen sensor may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the exhaust manifold heat shield. 2. Disconnect the oxygen sensor harness connector. 3. Remove the oxygen sensor. INSTALLATION PROCEDURE 1. Coat the threads of the oxygen sensor with anti-seize compound, if necessary. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will have the compound applied to the threads. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied before installation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2665 2. Install the oxygen sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the oxygen sensor to 30 N.m (22 lb ft). 3. Connect the oxygen sensor harness connector. 4. Install the exhaust manifold heat shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2666 Oxygen Sensor: Service and Repair Post Catalytic Converter REMOVAL PROCEDURE NOTE: The Heated Oxygen Sensors each use a permanently attached pigtail and connector. This pigtail should not be removed from the heated oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the heated oxygen sensor. - Take care when handling the rear heated oxygen sensor (HO2S 2). The in-line connector and louvered end must be kept free of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S 2. 1. Turn OFF the ignition. 2. Disconnect the HO2S 2 connector, in the Engine Compartment. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Carefully remove the HO2S 2. NOTE: The use of excessive force may damage the threads in the exhaust manifold/pipe. INSTALLATION PROCEDURE IMPORTANT: A special anti-seize compound is used on the HO2S 2 threads. The compound consists of a liquid graphite and glass beads. The graphite will burn away but the glass beads will remain, making the sensor easier to remove. New or service sensors already have the compound applied to the threads. If the sensor is removed and is to be reinstalled, the threads must be coated with an anti-seize compound before reinstallation. 1. Coat the threads only of the HO2S 2 with anti-seize compound, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Pre Catalytic Converter > Page 2667 2. Install the HO2S 2. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the HO2S 2 to 41 N.m (30 lb ft). 3. Lower the vehicle. 4. Reconnect the HO2S 2 connector, in the engine compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2671 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2672 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2676 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2677 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2684 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2685 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2689 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2690 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2699 Catalytic Converter: Service and Repair Catalytic Converter Replacement Removal Procedure Notice: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Support the three way catalytic converter. 3. Remove the intermediate pipe bolts. 4. Remove the exhaust manifold bolts. 5. Remove the three way catalytic converter bracket bolt. 6. Remove the three way catalytic converter and seals. 7. Clean the flange surfaces. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 2700 1. Install the three way catalytic converter seals. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the intermediate pipe bolts. ^ Tighten the intermediate pipe bolts to 30 Nm (22 ft. lbs.). 3. Install the three way catalytic converter to the exhaust manifold. ^ Tighten the exhaust manifold pipe bolts to 45 Nm (33 ft. lbs.). 4. Install three-way catalytic converter bracket bolt. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the evaporative emission (EVAP) canister purge valve harness connector. 2. Disconnect the vacuum pipe from the EVAP canister purge valve. 3. Disconnect the purge pipe from the EVAP canister purge valve. 4. Remove the EVAP canister purge valve and bracket. 5. Remove the EVAP canister purge valve from the purge bracket. 6. Inspect for carbon release in the EVAP canister purge valve ports. Refer to Evaporative Emission (EVAP) System Cleaning. INSTALLATION PROCEDURE 1. Install the EVAP canister purge valve on to the purge bracket. 2. Install the EVAP canister purge valve and bracket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the purge bracket nut to 8 N.m (71 lb in). 3. Connect the purge pipe to the EVAP canister purge valve. 4. Connect the vacuum pipe to the EVAP canister purge valve. 5. Connect the EVAP canister purge valve harness connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2708 Evaporative Emission Canister Purge (EVAP) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 2709 Canister Purge Solenoid: Description and Operation EVAP VENT VALVE The EVAP vent valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module will command the valve closed during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Evaporative (EVAP) Emission Hose Routing Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 2714 Evaporative Emission Canister Vent (EVAP) Solenoid Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 2715 Canister Vent Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER VENT VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Loosen the EVAP canister vent valve hose clamp and slide the clamp down the hose away from the EVAP vent valve hose connection. 3. Remove the hose from the EVAP canister vent valve. 4. Remove the EVAP canister vent valve by placing a pry bar between the valve and mounting surface, and moving the valve forward. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 2716 5. Remove the clip from the EVAP canister vent valve harness connector. 6. Disconnect the EVAP canister vent valve harness connector. INSTALLATION PROCEDURE 1. Connect the EVAP canister vent valve harness connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 2717 2. Install the clip into the EVAP canister vent valve harness connector. 3. Install the EVAP canister vent valve by pushing the mounts into the original holes. 4. Lubricate the hose end with lubricant. 5. Install the hose to the EVAP canister vent valve. 6. Slide the EVAP canister vent valve hose clamp down on to the hose connection at the EVAP canister vent valve. 7. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) Evaporative Emissions Hose: Service and Repair Engine (Purge Pipe) REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Disconnect the engine purge pipe from the evaporative emission (EVAP) canister purge valve. 3. Disconnect the engine purge pipe from the chassis purge pipe. 4. Remove the engine purge pipe. INSTALLATION PROCEDURE 1. Position the engine purge pipe to the EVAP canister purge valve and the chassis purge pipe. 2. Connect the engine purge pipe to the chassis purge pipe. 3. Connect the engine purge pipe to the EVAP chassis purge valve. 4. Install the air cleaner assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) > Page 2722 Evaporative Emissions Hose: Service and Repair Engine (Vacuum Pipe) REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine purge vacuum pipe from the intake manifold. 3. Disconnect the engine purge vacuum pipe from the EVAP canister purge valve. 4. Remove the engine purge vacuum pipe. INSTALLATION PROCEDURE 1. Place the engine purge vacuum pipe to the EVAP canister purge valve and intake manifold. 2. Connect the engine purge vacuum pipe to the EVAP canister purge valve. 3. Connect the engine purge vacuum pipe to the intake manifold. 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) > Page 2723 Evaporative Emissions Hose: Service and Repair Canister/Fuel Tank REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the evaporative emissions (EVAP) vapor pipe from the fill limiter vent valve, and fuel sender assembly. 3. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Position the EVAP vapor pipe on the fuel tank 2. Connect the EVAP vapor pipe to the fill limiter vent valve, and the fuel sender assembly. 3. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) > Page 2724 Evaporative Emissions Hose: Service and Repair Engine/Chassis REMOVAL PROCEDURE 1. Disconnect the chassis purge pipe from the engine purge pipe. 2. Plug the engine purge pipe and chassis purge pipe to prevent contamination. 3. Raise the vehicle. Refer to Vehicle Lifting. 4. Disconnect the chassis purge pipe from the canister purge pipe. 5. Plug the canister purge pipe and chassis purge pipe to prevent contamination. 6. Remove the exhaust heat shield. 7. Remove the fuel bundle mounting bolts from the body clips. 8. Remove the chassis purge pipe from the body clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) > Page 2725 9. Remove the chassis purge pipe (1) to be serviced. INSTALLATION PROCEDURE 1. Install the chassis purge pipe and hardware (1). NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > Engine (Purge Pipe) > Page 2726 2. Position the chassis purge pipe in the body clips. 3. Install the fuel bundle mounting bolts into the body clips. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 6 N.m (53 lb in). 4. Install the exhaust heat shield. Tighten Tighten the exhaust shield bolt to 2 N.m (18 lb in). - Tighten the exhaust shield nuts to 1 N.m (9 lb in). 5. Remove the caps on the chassis purge pipe and canister purge pipe. 6. Connect the chassis purge pipe to the canister purge pipe. 7. Lower the vehicle. 8. Remove the caps on the engine purge pipe and chassis purge pipe. 9. Connect the chassis purge pipe to the engine purge pipe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Crankcase Ventilation Hoses/Pipes Replacement Removal Procedure 1. Disconnect the crankcase ventilation hose from the camshaft cover. 2. Disconnect the crankcase ventilation hose from the intake manifold. Installation Procedure 1. Connect the crankcase ventilation hose to the camshaft cover. 2. Connect the crankcase ventilation hose to the intake manifold. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 345-414 kPa (50-60 psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2737 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2738 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Steps 1 - 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2739 Step 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2740 Steps 4 - 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2741 Steps 8 - 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2742 Steps 10 - 12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2743 Steps 13 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2744 Steps 15 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2745 Steps 19 - 21 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2751 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2752 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Remove the left sound insulator. 2. Disconnect the release cable (1) retainer from the lever assembly. 3. Remove the retaining nuts. 4. Remove the pedal assembly (2). INSTALLATION PROCEDURE 1. Install the pedal assembly (2) to the cowl. 2. Install the retaining nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 30 N.m (22 lb ft). 3. Slip the accelerator cable (1) through the slot in the rod and then install the retainer in the rod, being sure that the retainer is seated. 4. Install the left sound insulator. 5. Inspect for correct opening and closing positions by operating the accelerator pedal. Make sure that the throttle valve reaches a wide open throttle (WOT) position. If not, inspect for a damaged or bent bracket, lever, or other component, or for carpet under the accelerator pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the outlet splash shield from the air cleaner. 2. Remove the left headlamp assembly. 3. Remove the upper push-in retainer (1) from the front air cleaner intake duct. 4. Remove the left front tire and wheel. 5. Remove the left front wheel house panel. 6. Remove the lower push-in retainer (4) from the front air cleaner intake duct. 7. Remove the front air cleaner intake duct (3) through the headlamp assembly opening. 8. Remove the resonator rear push-in retainer and the upper attaching bolt (5). 9. Remove the resonator assembly through the wheel house opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 2763 1. Install the resonator assembly through the wheel house opening. 2. Install the resonator rear push-in retainer and the upper attaching bolt (5). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (61 lb in). 3. Install the front air cleaner intake duct (3) through the headlamp assembly opening. 4. Install the lower push-in retainer (4) to the front air cleaner intake duct. 5. Install the left front wheel house panel. 6. Install the left front tire and wheel. 7. Lower the vehicle. 8. Install the upper push-in retainer (1) to the front air cleaner intake duct. 9. Install the headlamp assembly. 10. Install the air cleaner outlet splash shield. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2772 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2778 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2784 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2785 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2786 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2792 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2793 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 2794 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2795 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper air cleaner screws. 2. Remove the upper air cleaner cover (1). 3. Remove the air cleaner filter (2) from lower air cleaner housing (3). 4. Inspect the air cleaner filter for dust, dirt and water. 5. Replace if required. INSTALLATION PROCEDURE 1. Install the air cleaner filter (2) into the lower air cleaner housing (3). 2. Install the upper air cleaner cover (1) to lower air cleaner housing. 3. Install the upper air cleaner screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the upper air cleaner cover screws to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2800 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2801 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2802 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2803 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2804 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2805 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2806 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 2807 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 2808 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and hear heavy knocking, your engine needs service. GASOLINE SPECIFICATIONS It is recommended that gasoline meet specifications which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm. Gasoline meeting these specifications could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the "Auto Makers' Choice" label on the pump. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasoline contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasoline that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 2809 Fuel: Description and Operation FUEL SYSTEM SPECIFICATIONS Use regular unleaded gasoline rated at 87 octane or higher. It is recommended that the gasoline meet specifications which have been developed by the American Automobile Manufacturers Association (AAMA) and endorsed by the Canadian Motor Vehicle Manufacturers Association for better vehicle performance and engine protection. Gasoline meeting the AAMA specification could provide improved driveability and emission control system performance compared to other gasolines. For more information, write to: American Automobile Manufacturer's Association, 7430 Second Ave, Suite 300, Detroit MI 48202. Be sure the posted octane is at least 87. If the octane is less than 87, you may get a heavy knocking noise when you drive. If the knocking is bad enough, the knock can damage your engine. If you are using fuel rated at 87 octane or higher and you hear heavy knocking, your engine needs service. Do not worry if you hear a little pinging noise when you are accelerating or driving up a hill. That is normal, and you do not have to buy a higher octane fuel to get rid of pinging. However, if there is a heavy, constant knock that means you have a problem. NOTE: Your vehicle was not designed for fuel that contains methanol. Do not use methanol fuel which can corrode metal parts in your fuel system and also damage plastic and rubber parts. This kind of damage would not be covered under your warranty. If your vehicle is certified to meet to meet California Emission Standards, indicated on the under hood emission control label, your vehicle is designed to operate on fuels that meet California specifications. If such fuels are not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp (MIL) on your instrument panel may turn ON and/or your vehicle may fail a smog-check test. If this occurs, return to your authorized dealer for diagnosis to determine the cause of failure. In the event there is a determination that the cause of the condition is the type of fuels used, repairs may not be covered by your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT). Ask your service station operator whether or not the fuel contains MMT. General Motors does not recommend the use of such gasolines. If fuels containing MMT are used, spark plug life may be affected. The malfunction indicator lamp on your instrument panel may turn on. If this occurs, return to your authorized dealer for service. To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent deposits from forming in your engine and fuel system, allowing your emission control system to function properly. Therefore, you should not have to add anything to the fuel. In addition, gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area to contribute to clean air. General Motors recommends that you use these gasolines, particularly if they comply with the specifications described earlier. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool Fuel: Testing and Inspection With Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethenol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components and fuel filter restriction. TEST PROCEDURE 1. Test the fuel composition Using J 44175 Fuel Composition Tester and J 41175-3 Instruction Manual. 2. If water appears in the fuel sample, perform the following steps 2.1 Clean the fuel system. Refer to Fuel System Cleaning. 2.2. Replace the fuel filter. 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the Fuel Composition Test Examples table. 4. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If testing shows the ethanol percentage is still more than 15 percent replace the fuel in the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > With Special Tool > Page 2812 Fuel: Testing and Inspection Without Special Tool ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL) TEST DESCRIPTION Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. ALCOHOL IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. PARTICULATE CONTAMINANTS IN FUEL TESTING PROCEDURE The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. II the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Refer to Fuel System Cleaning. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being over-tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. - Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2822 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2823 Fuel Pressure Release: Service and Repair Fuel System Pressure Relief TOOLS REQUIRED J 34730-1A Fuel Pressure Gage 1. Disconnect the negative battery cable. 2. Connect the J 34730-1A to the fuel pressure connection. 3. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 4. Disconnect the fuel pressure gage from the fuel pressure connection. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2828 Fuel Injector: Diagrams Fuel Injector 1 Fuel Injector 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2829 Fuel Injector 2 Fuel Injector 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2830 Fuel Injector: Description and Operation The fuel injector assembly is a solenoid device controlled by the control module that meters pressurized fuel to a single engine cylinder. The control module energizes the high-impedance, 12 ohms, injector solenoid (4) to open a normally closed ball valve (1). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate (3) at the injector outlet. The director plate has machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip (2). Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This fine atomization improves fuel economy and emissions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. TEST Steps 1-4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2833 Steps 5-7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2834 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL SYSTEM DESCRIPTION The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2835 Steps 5-8 The number below refers to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2836 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 SYSTEM DESCRIPTION The scan tool is first used to energize the fuel pump relay. The scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Steps 1-4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2837 Steps 5-8 The number below reters to the step number on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 2838 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis FUEL INJECTOR CIRCUIT DIAGNOSIS CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST Steps 1-7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure FUEL INJECTOR CLEANING PROCEDURE TOOLS REQUIRED - J 37287 Fuel Line Shut-Off Adapters - J 38500-A Fuel Injector Cleaner - J 42873-1 3/8 Fuel Line Shut-Off Adapter - J 42873-2 5/16 Fuel Line Shut-Off Adapter - J 42964-1 3/8 Fuel Line Shut-Off Adapter - J 42964-2 5/16 Fuel Line Shut-Off Adapter IMPORTANT: GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. - Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. - Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure. - During this procedure you will need a total of 960 ml (32.4 Oz) of cleaning solution. That is 2 tanks of solution for the J 38500-A. Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 Oz) of solution to insure complete injector cleaning. 1. Obtain J 38500-A (2). IMPORTANT: Make sure the valve at the bottom of the canister (3) is closed. 2. For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 38500-A. 3. For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 38500-A. 4. If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline. 5. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 6. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 7. Disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, or J 42964-1 and J 42964-2, or J 42873-1 and J 42873-2 as appropriate for the fuel system. 8. Connect the J 38500-A to the vehicle's fuel rail. 9. Pressurize the J 38500-A to 510 kPa (75 psi). 10. Start and idle the engine until it stalls, due to lack fuel. This should take approximately 15-20 minutes. 11. Disconnect J 38500-A from the fuel rail. 12. Reconnect the vehicle's fuel pump relay and oil pressure switch connector, if equipped. 13. Remove J 37287, or J 42964-1, and J 42964-2, or J 42873-1 and J 42873-2 and reconnect the vehicles fuel feed and return lines. 14. Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector. 16. Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2841 17. Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicles fuel tank for each gallon of gasoline estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. 18. Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 3,000 miles. GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure. 19. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2842 Fuel Injector: Service and Repair Fuel Injector Replacement REMOVAL PROCEDURE 1. Remove the fuel rail. 2. Remove the fuel injector electrical connector. 3. Remove the fuel injector retainer clip (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2843 4. Remove the fuel injector from the fuel rail. 5. Remove and discard the fuel injector O-rings. IMPORTANT: Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring in not removed, remove the O-ring from the fuel rail assembly. - If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, new insulator cups must be installed. INSTALLATION PROCEDURE 1. If the fuel injector insulator cups (1) are removed from the cylinder head while removing the fuel rail, new insulator cups must be installed. 2. Install the O-rings on the fuel injector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 2844 IMPORTANT: Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil. 3. Install the fuel injector. 4. Install the fuel injector clip (1). 5. Install the fuel injector electrical connector. 6. Install the fuel rail. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions CAUTION: - Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. - In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 2848 Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) TOOLS REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the retainer from the quick-connect fitting, if applicable. 3. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 4. Choose the correct tool from J 37088-A tool set for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 2851 5. Pull the connection apart. 6. Using a clean shop towel, wipe off the male pipe end. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE 1. Apply a few drops of clean engine oil to the male pipe end. CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 2852 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to make sure the connection is secure. 4. Install the retainer to the quick-connect fitting, if applicable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 2853 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Blow dirt out of the fitting using compressed air. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury. 3. Squeeze the plastic tabs of the male end connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 2854 4. Pull the connection apart. 5. Wipe off the male pipe end using a clean shop towel. NOTE: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. 6. Inspect both ends of the fitting for dirt and burrs. 7. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 2855 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place. 3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY The fuel pressure regulator is a diaphragm relief valve. The diaphragm has fuel pressure on one side and regulator spring pressure on the other side. Fuel pressure is controlled by a pressure balance across the regulator. The fuel system pressure is constant. A software bias compensates the injector on-time based on the signal from the MAP sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 2859 Fuel Pressure Regulator: Service and Repair REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the vacuum pipe from the fuel pressure regulator. 3. Place a shop towel under the fuel pressure regulator in order to catch any fuel spillage. 4. Remove the retaining bolt (1) from the fuel pressure regulator. 5. Remove the fuel pressure regulator. 6. Remove any seal or seal material left on the fuel rail. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 2860 1. Install the fuel pressure regulator to the fuel rail IMPORTANT: Lubricate the O-ring with clean engine oil before installation. 2. Install the fuel pressure regulator retaining bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining bolt to 10 N.m (89 lb in). 3. Connect the vacuum pipe to the fuel pressure regulator. 4. Connect the negative battery cable. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 2861 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition. 5.4. Inspect for fuel leaks. 6. Place the shop towel into a suitable storage container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 345-414 kPa (50-60 psi) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. - Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections. 1. Install the J 34730-1A to the fuel pressure connection, located on the fuel rail. 2. Place the bleed hose of the fuel pressure gage into an approved gasoline container. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. 3. Open the bleed valve on the fuel pressure gage in order to bleed the air from the gage. 4. Turn ON the ignition, with the engine OFF. 5. Command the fuel pump ON with a scan tool until all of the air is bled out of the gage. 6. Close the bleed valve on the fuel pressure gage. 7. Command the fuel pump ON with a scan tool. 8. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container and open the bleed valve to bleed fuel system pressure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2868 2. Place a shop towel under the fuel pressure gage to catch any remaining fuel spillage. 3. Remove the J 34730-1A from fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Install the cap on the fuel pressure connection. 6. Place the shop towel in an approved container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2869 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The control module enables the fuel pump relay when the ignition switch is turned ON. The control module will disable the fuel pump relay within two seconds unless the control module detects ignition reference pulses. The control module continues to enable the fuel pump relay as long as ignition reference pulses are detected. The control module disables the fuel pump relay within two seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST Steps 1 - 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2870 Step 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2871 Steps 4 - 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2872 Steps 8 - 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2873 Steps 10 - 12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2874 Steps 13 - 14 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2875 Steps 15 - 18 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2876 Steps 19 - 21 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation Fuel Pump Pickup Filter: Customer Interest Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2885 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2886 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2887 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation Fuel Pump Pickup Filter: All Technical Service Bulletins Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2893 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2894 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Pickup Filter: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 2895 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY The fuel rail assembly (1) attaches to the engine intake manifold. The fuel rail assembly performs the following functions: Positions the injectors (5) in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel pressure regulator into the fuel metering system Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2899 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Remove the engine fuel supply and return pipes. 3. Remove the air cleaner outlet resonator. 4. Disconnect the vent pipe from the fuel pressure regulator. 5. Remove the fuel pressure regulator bolt (1). 6. Remove the fuel pressure regulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2900 7. Disconnect the fuel injector harness connectors. 8. Remove the fuel rail attaching studs (1). 9. Remove the fuel rail using the following procedure: 9.1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports. 9.2. Rotate the fuel rail in order to position the injectors downward. 9.3. Remove the fuel rail. IMPORTANT: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips. 10. Remove the fuel injectors from the fuel rail. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2901 1. If the fuel injector insulator cups (1) are removed from the cylinder head while removing the fuel rail, new insulator cups must be installed. 2. Install the fuel injectors to the fuel rail. 3. Install the fuel rail using the following procedure: 3.1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. 3.2. Align the injectors by rotating the fuel rail forward. 3.3. Carefully push the fuel injectors into the cylinder head ports. IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold. 4. Install the fuel rail attaching studs (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel rail studs to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2902 5. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place. 6. Install the fuel supply and return pipes. 7. Install the fuel pressure regulator. 8. Install the fuel pressure regulator bolt (1). Tighten Tighten the fuel pressure regulator bolt to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 2903 9. Connect the vent pipe to the fuel pressure regulator. 10. Install the air cleaner outlet resonator. 11. Connect the negative battery cable. 12. Inspect for fuel leaks using the following procedure: 12.1. Turn ON the ignition, with the engine OFF for 2 seconds. 12.2. Turn OFF the ignition for 10 seconds. 12.3. Turn ON the ignition. 12.4. Inspect for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment REMOVAL PROCEDURE 1. Relieve the fuel system pressure. 2. Disconnect the engine fuel pipes from the engine fuel flex hoses. 3. Use a back up wrench on the fuel pressure regulator and disconnect the return line. 4. Disconnect the fuel feed line from the fuel rail. 5. Remove the engine fuel pipes fasteners (1) located on the engine. 6. Remove the engine fuel pipes. INSTALLATION PROCEDURE 1. Install the fuel return pipe to the pressure regulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 2908 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Using a backup wrench on the fuel pressure regulator tighten the return pipe to 10 N.m (89 lb in). 2. Connect the fuel feed pipe to the fuel rail. 3. Pull back on the fuel feed pipe to ensure that it has connected. 4. Install the engine fuel pipes fasteners located on the engine. Tighten Tighten the fuel pipes fasteners to 10 N.m (89 lb in). 5. Connect the engine fuel pipes to the engine fuel flex hoses. 6. Connect the negative battery cable. 7. Inspect for leaks using the following procedure: 7.1. Turn ON the ignition, with the engine OFF for 2 seconds. 7.2. Inspect for fuel leaks. 7.3. Turn OFF the ignition for 10 seconds. 7.4. Turn ON the ignition. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 2909 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis REMOVAL PROCEDURE 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Disconnect the quick-connect fittings at the engine compartment fuel feed and return pipes. 3. Plug the fuel pipes. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Disconnect the quick-connect fittings at the fuel sender fuel feed and return connecting pipes. 7. Remove the fuel pipe mounting bolts from the body clips. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the pipe removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including the hose overlap on the fuel pipe. 8. Remove the fuel pipes from the body clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 2910 9. Remove the fuel pipes (1). INSTALLATION PROCEDURE 1. Install the fuel pipes (1). 2. Position the fuel pipes in the body clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Engine Compartment > Page 2911 3. Install the fuel pipe mounting bolts into the body clips. NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 6 N.m (53 lb in). 4. Install the exhaust heat shield. Tighten Tighten the exhaust shield bolt to 2 N.m (18 lb in). - Tighten the exhaust shield nuts to 1 N.m (9 lb in). 1. Remove the caps on the fuel pipes. 2. Connect the quick-connect fittings at the fuel sender pipes. 3. Lower the vehicle. 4. Connect the quick-connect fittings at engine compartment fuel feed and return pipes. 5. Connect the negative battery cable. 6. Inspect for fuel leaks using the following procedure: 6.1. Turn ON the ignition, with the engine OFF for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair Fuel Filler Hose: Service and Repair FILLER TUBE REPLACEMENT REMOVAL PROCEDURE NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel fill cap. 2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. 3. Remove the fuel filler pipe retainers from the fuel filler pipe access panel. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Loosen the fuel filler hose clamps at the fuel tank and fuel fill tube. 6. Remove the fuel filler hose. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 2916 7. Remove the fuel filler pipe attaching screw from the under body. 8. Remove the fuel filler pipe. INSTALLATION PROCEDURE 1. Install the fuel filler pipe. 2. Install the fuel filler pipe attaching screw to the under body. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel filler pipe attaching screw to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Page 2917 3. Install the fuel filler hose. 4. Position the fuel filler hose clamp at the fuel tank and fuel fill tube. Tighten Tighten the fuel tank filler hose clamps to 3 N.m (27 lb in). 5. Lower the vehicle. 6. Install the fuel filler pipe retainers to the fuel filler pipe access panel. 7. Install the fuel filler cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 2921 Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 2922 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 2923 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 2924 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 2928 Fuel Tank Unit: Service Precautions CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly . Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 2929 Fuel Tank Unit: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: The fuel level sensor (4) - The fuel tank pressure (FTP) sensor (1) - The fuel pump module (2) - The fuel strainer (3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 2930 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39765 Fuel Sender Lock Nut Wrench REMOVAL PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly. 1. Remove the fuel tank (4). 2. Disconnect the wiring harness from the fuel sender and the fuel tank pressure (FTP) sensor. 3. Use the J 39765 in order to press down and rotate the retaining ring (1). IMPORTANT: The modular fuel sender assembly may spring up. - When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. - Carefully discard the reservoir fuel into an approved container. 4. Remove the fuel sender assembly. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 2931 1. Install the new seal on the fuel tank (4). 2. Align the fuel pipes parallel with the mark on the fuel tank. 3. Slowly apply pressure to the top of the spring loaded sender until the sender aligns flush with the retainer on tank. 4. Install the retaining ring (1) using the J 39765. IMPORTANT: Be sure that the retaining ring is fully seated within the tab slots. 5. Connect the wiring harness to the fuel sender and the FTP sensor. 6. Install the fuel tank. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2935 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts 10 allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2936 Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2937 Steps 7-11 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2938 Steps 12-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2939 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the idle air control (IAC) valve harness connector (1). 3. Remove the IAC valve screw. 4. Remove the IAC valve and seal. Cleaning and Inspection Procedure If using the original IAC valve, perform the following inspection and cleaning procedure: Clean the IAC valve sealing surface, pintle valve seat and air passage in the throttle body. - Whenever the air passages have heavy deposits, remove the throttle body for a complete cleaning. - The IAC valve may be cleaned by using a shop towel or small parts cleaning brush to remove heavy deposits. - Shiny spots on the pintle or seat are normal, and not an indication of a misaligned pintle shaft. - Inspect the IAC valve seal for cuts, cracks or distortion. Replace the IAC valve if the seal is damaged. - Whenever installing a new IAC valve, replace the valve with an identical part. The IAC valve pintle shape and diameter are specific to this application. - Compare the distance between the tip, or the pintle, and the mounting flange of the new and old IAC valves. Use finger pressure to slowly retract the pintle of the new valve to the distance of the old. This will not cause damage to the new IAC valve but is critical for installation. INSTALLATION PROCEDURE 1. Lubricate the IAC valve seal with clean engine oil. 2. Install the IAC valve into the throttle body. 3. Install the IAC valve screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new screw when replacing the IAC valve. Tighten Tighten the IAC valve screw to 3 N.m (27 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 2940 4. Connect the IAC valve harness connector (1). 5. Install the air cleaner outlet resonator. 6. Reset the IAC valve pintle using the following procedure: 6.1. Turn ON the ignition, with the engine OFF. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Start the engine and check for proper idle operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair Resonator: Service and Repair AIR CLEANER OUTLET RESONATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the air cleaner duct from the air cleaner resonator. 2. Loosen the air cleaner outlet resonator to throttle body clamp (3), accessed through the accelerator bracket (2) slot. 3. Disconnect the intake air temperature (IAT) sensor harness connector (4). 4. Disconnect the vacuum pipe from the air cleaner resonator. 5. Loosen the vent hose clamp and move it away from the air cleaner resonator (2). 6. Disconnect the vent hose (1) from the air cleaner resonator (2). 7. Remove the air cleaner resonator (2) from the throttle body (3). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Resonator, Intake Air > Component Information > Service and Repair > Page 2944 1. Install the air cleaner resonator to the throttle body. 2. Connect the vent hose to the air cleaner resonator. 3. Move the spring clamp over the air cleaner resonator vent port and vent hose. 4. Tighten the resonator to throttle body clamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the clamp to 5 N.m (44 lb in). 5. Connect the IAT sensor harness connector. 6. Connect the vacuum pipe to the air cleaner resonator. 7. Connect the air cleaner intake duct to the air cleaner resonator. Tighten Tighten the air cleaner intake duct clamp to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2949 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2950 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair Throttle Body: Service and Repair THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. - Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 1. Remove the air cleaner resonator. 2. Disconnect the idle air control (IAC) valve harness connector. 3. Disconnect the throttle position (TP) sensor harness connector. 4. Disconnect the vacuum hoses at the throttle body. 5. Remove the accelerator control bracket and cables from the throttle body. 6. Remove the throttle body attaching bolts and studs (1). 7. Remove the throttle body (4) from the intake manifold. INSTALLATION PROCEDURE 1. Inspect the throttle body gasket (3) and replace if necessary. 2. Install the throttle body (4) to the intake manifold. 3. Install the throttle body attaching bolts and studs (5). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Page 2954 NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the throttle body attaching bolts and studs to 10 N.m (89 lb in). 4. Install the accelerator cable bracket and cables. 5. Connect the vacuum hoses to the throttle body. 6. Connect the TP sensor harness connector. 7. Connect the IAC valve harness connector. 8. Install the air cleaner resonator. 9. Test the accelerator movement by depressing the pedal to the floor and releasing the pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Replacement REMOVAL PROCEDURE 1. Depress the accelerator control cable tangs (1) from the pedal lever assembly. 2. Remove the accelerator control cable from the pedal lever assembly. 3. Remove the cruise control cable (1), if applicable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2959 4. Release the accelerator control cable lug (3) from the throttle body assembly (4). 5. Depress the tangs on the control cable (2) while pulling the cable through the control cable bracket (1). 6. Remove the control cable from the bracket. 7. Disconnect the control cable (2) from the support clip (1). 8. Remove the cable from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2960 1. Route the accelerator control cable (2) through the control cable bracket (1). 2. Press the cable tabs (2) into the bracket (1). Ensure the tangs expand and properly seat. 3. Install the control cable lug (3) to the throttle body cam. 4. Connect the cable (2) to the support clip (1). 5. Install the cruise control cable (2), if applicable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2961 6. Install the cable (1) to the pedal lever assembly. Ensure the tangs are fully expanded and seated. 7. Slip the accelerator cable through the slot in the rod of the accelerator pedal and install the retainer in the rod. Ensure the retainer is seated. 8. Ensure the cable is completely seated in the throttle cam past the retaining clips. 9. Inspect for the correct opening and closing positions by operating the accelerator pedal. Make sure that the throttle valve reaches wide-open throttle position. If not, inspect for damaged or a bent bracket or lever IMPORTANT: Flexible components, i.e. hoses, wires, conduits, etc., must not be routed within 50 mm (2.0 in) of the moving parts of the accelerator linkage outboard support unless the routing is positively controlled. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2962 Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Bracket Replacement REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). 3. Disconnect the accelerator control cable (3) from the throttle body (4) and accelerator bracket (1). 4. Remove the 2 accelerator bracket nuts (3). 5. Remove the accelerator bracket (2) from the throttle body (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2963 INSTALLATION PROCEDURE 1. Install the accelerator bracket (2) on the throttle body (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the accelerator bracket nuts to 10 N.m (89 lb in). 2. Connect the accelerator control cable (3) to the throttle body (4) and accelerator bracket (1). 3. Connect the cruise control cable (2) from the throttle body (3) and accelerator bracket (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 2964 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2968 Throttle Position (TP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2969 Throttle Position Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the air cleaner outlet resonator. 2. Disconnect the throttle position (TP) sensor harness connector (2). 3. Remove the throttle TP sensor screw. 4. Remove the TP sensor and seal. INSTALLATION PROCEDURE 1. With the throttle in the closed position, install the TP sensor and seal. 2. Install the TP sensor screw. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Install a new TP sensor screw when replacing the TP sensor. Tighten Tighten the TP sensor screw to 2 N.m (18 lb in). 3. Connect the TP sensor harness connector (2). 4. Install the air cleaner outlet resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2974 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2975 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2976 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2979 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2980 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation Ignition Coil: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS 1. Ignition Control Module (ICM) 2. Compression Sense Ignition (CSI) Pickup 3. Not Used 4. 2-3 Coil Control 5. Ignition Voltage 6. 1-4 Coil Control 7. Not Used 8. Interconnect Each ignition coil is responsible for supplying secondary energy to a pair of spark plugs. The ignition control signals output by the PCM are amplified by the ICM in order to fire each coil. The spark events are triggered by the ICM, but the module has no influence on spark timing. The ICM is also responsible for detecting and supplying a camshaft position (CMP) signal pulse to the PCM to be used for sequential fuel injection. This ignition system does not use a conventional CMP sensor that detects valve train position. The ICM detects when either cylinder 1 or cylinder 3 has fired on the cylinders compression stroke using sensing circuitry integrated within each coil. The sensing circuit detects the polarity and the strength of the secondary voltage output, the higher output is always at the event cylinder. The ICM sends a CMP signal to the PCM based on the voltage difference between the event and waste cylinder firing energy. This system is called compression sense ignition. By monitoring the camshaft position and crankshaft position (CKP) signals the PCM can accurately time the operation of the fuel injectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 2984 Ignition Coil: Service and Repair IGNITION COIL HOUSING REPLACEMENT REMOVAL PROCEDURE 1. Remove the accelerator and cruise control cables from the bracket, if equipped. 2. Remove the bracket. 3. Remove the ignition control module (ICM). 4. Remove the ignition coil housing retaining bolts. 5. Remove the ignition coil housing from the camshaft cover. INSTALLATION PROCEDURE 1. Install the ignition coil housing to the camshaft cover. 2. Install the ignition coil housing retaining bolts. NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining bolts to 10 N.m (89 lb in). 3. Install the ICM. 4. Install the accelerator and cruise control cables bracket. 5. Install the accelerator and cruise control cables bracket bolts. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 2985 Tighten Tighten the retaining bolts to 10 N.m (89 lb in). 6. Install the accelerator and cruise control cables to the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 2989 Ignition Control Module (ICM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 2990 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS 1. Ignition Control Module (ICM) 2. Compression Sense Ignition (CSI) Pickup 3. Not Used 4. 2-3 Coil Control 5. Ignition Voltage 6. 1-4 Coil Control 7. Not Used 8. Interconnect Each ignition coil is responsible for supplying secondary energy to a pair of spark plugs. The ignition control signals output by the PCM are amplified by the ICM in order to fire each coil. The spark events are triggered by the ICM, but the module has no influence on spark timing. The ICM is also responsible for detecting and supplying a camshaft position (CMP) signal pulse to the PCM to be used for sequential fuel injection. This ignition system does not use a conventional CMP sensor that detects valve train position. The ICM detects when either cylinder 1 or cylinder 3 has fired on the cylinders compression stroke using sensing circuitry integrated within each coil. The sensing circuit detects the polarity and the strength of the secondary voltage output, the higher output is always at the event cylinder. The ICM sends a CMP signal to the PCM based on the voltage difference between the event and waste cylinder firing energy. This system is called compression sense ignition. By monitoring the camshaft position and crankshaft position (CKP) signals the PCM can accurately time the operation of the fuel injectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 2991 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the accelerator cable from the bracket. 3. Remove the accelerator cable bracket bolt. 4. Remove the accelerator cable bracket. 5. Disconnect the ignition control module (ICM) harness connector. 6. Remove the ICM retaining screws. 7. Remove the ICM from the ignition coil housing. INSTALLATION PROCEDURE 1. Install the ignition control module in the ignition coil housing. IMPORTANT: Make sure the interconnect and seal are lined up before module installation. 2. Install the ICM retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 1.5 N.m (13 lb in). 3. Connect the ICM harness connector. 4. Install the accelerator cable bracket. 5. Install the accelerator cable bracket bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 2992 NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 10 N.m (18 lb in). 6. Install the accelerator cable to the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 2996 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 2997 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 2998 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3003 Ignition Control Module (ICM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3004 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS 1. Ignition Control Module (ICM) 2. Compression Sense Ignition (CSI) Pickup 3. Not Used 4. 2-3 Coil Control 5. Ignition Voltage 6. 1-4 Coil Control 7. Not Used 8. Interconnect Each ignition coil is responsible for supplying secondary energy to a pair of spark plugs. The ignition control signals output by the PCM are amplified by the ICM in order to fire each coil. The spark events are triggered by the ICM, but the module has no influence on spark timing. The ICM is also responsible for detecting and supplying a camshaft position (CMP) signal pulse to the PCM to be used for sequential fuel injection. This ignition system does not use a conventional CMP sensor that detects valve train position. The ICM detects when either cylinder 1 or cylinder 3 has fired on the cylinders compression stroke using sensing circuitry integrated within each coil. The sensing circuit detects the polarity and the strength of the secondary voltage output, the higher output is always at the event cylinder. The ICM sends a CMP signal to the PCM based on the voltage difference between the event and waste cylinder firing energy. This system is called compression sense ignition. By monitoring the camshaft position and crankshaft position (CKP) signals the PCM can accurately time the operation of the fuel injectors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3005 Ignition Control Module: Service and Repair REMOVAL PROCEDURE 1. Turn OFF the ignition. 2. Remove the accelerator cable from the bracket. 3. Remove the accelerator cable bracket bolt. 4. Remove the accelerator cable bracket. 5. Disconnect the ignition control module (ICM) harness connector. 6. Remove the ICM retaining screws. 7. Remove the ICM from the ignition coil housing. INSTALLATION PROCEDURE 1. Install the ignition control module in the ignition coil housing. IMPORTANT: Make sure the interconnect and seal are lined up before module installation. 2. Install the ICM retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 1.5 N.m (13 lb in). 3. Connect the ICM harness connector. 4. Install the accelerator cable bracket. 5. Install the accelerator cable bracket bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 3006 NOTE:Refer to Fastener Notice in Service Precautions. Tighten Tighten the retaining screws to 10 N.m (18 lb in). 6. Install the accelerator cable to the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3011 Crankshaft Position (CKP) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3012 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor is a variable reluctance sensor. The crankshaft position (CKP) sensor indicates the crankshaft speed and position. The CKP sensor produces an AC voltage of different amplitude and frequency. The frequency depends on the velocity of the crankshaft. The AC voltage output depends on the crankshaft position and battery voltage. The CKP sensor works in conjunction with a 7X reluctor wheel attached to the crankshaft. The CKP sensor connects to the powertrain control module (PCM) through the following circuits: The CKP sensor signal - The low reference TEST Steps 1-6 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3013 Steps 7-13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTCs P1336, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. Observe the fuel cut-off specifications for that engine. 5. The scan tool instructs you to perform the following: - Accelerate to wide open throttle (WOT). - Release when the fuel cut-off occurs. - Engine should not accelerate beyond calibrated RPM value. - Release throttle immediately if value is exceeded. - Block drive wheels. - Set parking brake. - DO NOT apply brake pedal. - Cycle the ignition from OFF to ON. - Apply and hold the brake pedal. - Start and idle engine. - Turn A/C OFF. - Vehicle must remain in Park or Neutral. - The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: Crankshaft position (CKP) sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. - Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. - Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 6. Enable the crankshaft position system variation learn procedure with the scan tool. 7. Accelerate to WOT. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 8. Release when the fuel cut-off occurs. 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P1336 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P1336 failed or did not run, refer to DTC P1336. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC that set. 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3016 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement REMOVAL PROCEDURE 1. Disconnect the battery. 2. Raise the vehicle. Refer to Vehicle Lifting 3. Remove the front air deflector, if applicable. 4. Remove the starter. 5. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 6. Remove the CKP sensor bolt. 7. Remove the CKP sensor. INSTALLATION PROCEDURE 1. Inspect the CKP sensor O-ring and lubricate with a mineral based grease. 2. Gently insert the CKP sensor into the block. 3. Install the CKP sensor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the CKP sensor bolt to 8 N.m (71 lb in). 4. Reconnect the CKP sensor electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3017 5. Reinstall the starter. 6. Reinstall the front air deflector, if removed in previous step. 7. Lower the vehicle. 8. Reconnect the battery. 9. Perform the CKP system Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Engine Compartment ICM And Sensors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3021 Knock Sensor (KS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3022 Knock Sensor: Description and Operation PURPOSE The knock sensor (KS) system enables the powertrain control module (PCM) to control the ignition timing advance for the best possible performance while protecting the engine from potentially damaging levels of detonation. The sensors in the KS system are used by the PCM as microphones to listen for abnormal engine noise that may indicate pre-ignition/detonation. SENSOR DESCRIPTION There are 2 types of KS currently being used: The broadband single wire sensor - The flat response 2-wire sensor Both sensors use piezo-electric crystal technology to produce and send signals to the PCM. The amplitude and frequency of this signal will vary constantly depending on the vibration level within the engine. Flat response and broadband KS signals are processed differently by the PCM. The major differences are outlined below: All broadband sensors use a single wire circuit. Some types of controllers will output a bias voltage on the KS signal wire. The bias voltage creates a voltage drop the PCM monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside the bias voltage parameters. Another way to use the KS signals is for the PCM to learn the average normal noise output from the KS. The PCM uses this noise channel, and KS signal that rides along the noise channel, in much the same way as the bias voltage type does. Both systems will constantly monitor the KS system for a signal that is not present or falls within the noise channel. - The flat response KS uses a 2-wire circuit. The KS signal rides within a noise channel which is learned and output by the PCM. This noise channel is based upon the normal noise input from the KS and is known as background noise. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the KS signal, keeping the signal within the channel. If there is knock, the signal will range outside the noise channel and the PCM will reduce spark advance until the knock is reduced. These sensors are monitored in much the same way as the broadband sensors, except that an abnormal signal will stay outside of the noise channel or will not be present. KS diagnostics can be calibrated to detect faults with the KS diagnostic inside the PCM, the KS wiring, the sensor output, or constant knocking from an outside influence such as a loose or damaged component. In order to determine which cylinders are knocking, the PCM uses KS signal information when the cylinders are near top dead center (TDC) of the firing stroke. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3023 Knock Sensor: Service and Repair REMOVAL PROCEDURE 1. Remove the starter. 2. Disconnect the knock sensor (KS) harness connector. 3. Remove the KS retaining bolt. 4. Remove the KS. INSTALLATION PROCEDURE 1. Install the knock sensor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: The KS threaded surfaces must be clean before installation. Tighten Tighten the knock sensor retaining bolt to 25 N.m (18 lb ft). 2. Connect the knock sensor harness connector. 3. Install the starter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: Recalls Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3032 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Recalls for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3033 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3039 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3040 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3041 Spark Plug: Specifications Spark Plug Torque ............................................................................................................................... ................................................ 20.0 Nm (15.0 lb. ft.) Spark Plug Gap ................................................ ....................................................................................................................................... 1.06 mm (0.042 in.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3042 Spark Plug: Application and ID Spark Plug Type ........................................................................................................................................................ GM P/N 12569190 or AC P/N 41-981 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3043 Spark Plug: Testing and Inspection SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug. SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3044 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion - Reduced ignition system voltage output Weak coils Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3045 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3046 Spark Plug: Service and Repair REMOVAL PROCEDURE NOTE: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil housing. 2. Remove the spark plugs with a spark plug socket. IMPORTANT: Remove any water and debris from the spark plug holes before spark plug removal with compressed air. 3. Inspect the spark plugs. Refer to Spark Plug Inspection. INSTALLATION PROCEDURE 1. Gap the spark plug, using round wire type spark plug gap gage. GAP Adjust the spark plug gap to 1.14 mm (0.045 in). 2. Install the spark plugs with a spark plug socket. IMPORTANT: DO NOT coat the spark plugs with anti seize compound. Over torquing could occur and damage to the cylinder head threads may result. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 3047 Tighten Tighten the spark plugs to 20 N.m (15 lb in). 3. Install the ignition coil housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3054 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3055 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Under Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3059 Automatic Transmission Shift Lock Control Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3063 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 3066 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in earn of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3070 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3071 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams > Page 3080 Shift Indicator: Description and Operation SHIFT INDICATOR The IPC illuminates the shift indicator when the PCM determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3089 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3090 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3094 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3095 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3099 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3100 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3108 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3109 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3110 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-06-04-082 > Nov > 04 > Engine Controls - Driveability Issues Using CNG Fuel PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Driveability Issues Using CNG Fuel Bulletin No.: 04-06-04-082 Date: November 09, 2004 TECHNICAL Subject: Driveability Concerns After Deceleration with CNG Fuel, DTC P0171 (Reprogram PCM) Models: 2004 Chevrolet Cavalier with 2.2L 4 Cylinder Engine (VIN 6 - RPO L42) and Bi-Fuel Option (RPO KL6) Condition Some customers may comment on various driveability concerns, while operating in CNG (Compressed Natural Gas) mode, following a deceleration maneuver from 40 to 50 mph (64 to 80 km/h). This may result in the Service Engine Soon light coming on and a DTC P0171 (Fuel Trim System Lean) being set. In some very rare instances, the engine may stall at speeds less than 10 mph (16 km/h) after a long closed throttle deceleration. Correction Reprogram the PCM with the listed calibration or later. Part Number 12596936 The new calibration will be released beginning with TIS satellite data update version 9.0 for 2004, available September 4, 2004. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-06-04-063 > Sep > 04 > Engine Controls - Idle Flair/Deceleration Stall PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Idle Flair/Deceleration Stall File In Section: 06 - Engine/Propulsion System Bulletin No.: 04-06-04-063 Date: September, 2004 TECHNICAL Subject: Engine Idle Flair When Clutch Depressed or Decel Stall (Reprogram PCM) Models: 2003-2004 Chevrolet Cavalier 2004 Chevrolet Classic 2003-2004 Oldsmobile Alero 2003-2004 Pontiac Grand Am, Sunfire with 4 Cylinder 2.2L Engine (VIN F - RPO L61) Condition Some customers may comment on an engine idle flair when the clutch is depressed. Also, some customers may comment on a low speed engine decel stall when coming to a stop. Cause The flair may be caused by the vehicle entering stall saver mode when the clutch is depressed. The low speed engine decel stall is produced by an interaction between the engine control software and the AC motor. Correction Reprogram the PCM with the latest calibration available. The new calibration will be released beginning with TIS satellite data update version 6.0 for 2004 available June 2004. As always, make sure your TECH 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-06-04-082 > Nov > 04 > Engine Controls - Driveability Issues Using CNG Fuel PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Driveability Issues Using CNG Fuel Bulletin No.: 04-06-04-082 Date: November 09, 2004 TECHNICAL Subject: Driveability Concerns After Deceleration with CNG Fuel, DTC P0171 (Reprogram PCM) Models: 2004 Chevrolet Cavalier with 2.2L 4 Cylinder Engine (VIN 6 - RPO L42) and Bi-Fuel Option (RPO KL6) Condition Some customers may comment on various driveability concerns, while operating in CNG (Compressed Natural Gas) mode, following a deceleration maneuver from 40 to 50 mph (64 to 80 km/h). This may result in the Service Engine Soon light coming on and a DTC P0171 (Fuel Trim System Lean) being set. In some very rare instances, the engine may stall at speeds less than 10 mph (16 km/h) after a long closed throttle deceleration. Correction Reprogram the PCM with the listed calibration or later. Part Number 12596936 The new calibration will be released beginning with TIS satellite data update version 9.0 for 2004, available September 4, 2004. As always, make sure your TECH2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-06-04-063 > Sep > 04 > Engine Controls - Idle Flair/Deceleration Stall PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Idle Flair/Deceleration Stall File In Section: 06 - Engine/Propulsion System Bulletin No.: 04-06-04-063 Date: September, 2004 TECHNICAL Subject: Engine Idle Flair When Clutch Depressed or Decel Stall (Reprogram PCM) Models: 2003-2004 Chevrolet Cavalier 2004 Chevrolet Classic 2003-2004 Oldsmobile Alero 2003-2004 Pontiac Grand Am, Sunfire with 4 Cylinder 2.2L Engine (VIN F - RPO L61) Condition Some customers may comment on an engine idle flair when the clutch is depressed. Also, some customers may comment on a low speed engine decel stall when coming to a stop. Cause The flair may be caused by the vehicle entering stall saver mode when the clutch is depressed. The low speed engine decel stall is produced by an interaction between the engine control software and the AC motor. Correction Reprogram the PCM with the latest calibration available. The new calibration will be released beginning with TIS satellite data update version 6.0 for 2004 available June 2004. As always, make sure your TECH 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3138 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3139 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Under Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3143 Automatic Transmission Shift Lock Control Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3147 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 3150 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in earn of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3154 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3155 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3161 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3162 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Under Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3166 Automatic Transmission Shift Lock Control Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3170 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 3173 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in earn of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3177 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3178 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 3187 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3192 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3193 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 3199 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3204 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3205 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Replacement Low/Reverse Servo Assembly Replacement Removal Procedure 1. Remove the oil feed pipes. 2. Remove the 3 low and reverse band servo cover bolts, the servo and the spring. 3. Disassemble, clean and inspect the low and reverse servo assembly. Installation Procedure 1. Assemble the low and reverse servo. Notice: Refer to Fastener Notice in Service Precautions 2. Install the lo and the reverse band servo cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil feed pipe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo Assembly Replacement > Page 3208 Band Apply Servo: Service and Repair Intermediate/Fourth Servo Assembly Replacement Intermediate/Fourth Servo Assembly Replacement Removal Procedure Caution: Refer to Vehicle Lifting. 1. Raise the vehicle. Support the vehicle. 2. Remove the oil pan and filter. 3. Remove the oil feed pipes. 4. Remove the two intermediate/4th servo cover bolts, the servo and the spring. 5. Disassemble, clean and inspect the intermediate/4th servo assembly. Installation Procedure 1. Assemble the intermediate/4th servo assembly. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the intermediate/4th band servo piston spring, the servo and the servo cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). 3. Install the oil feed pipes. 4. Install the filter and the pan. 5. Lower the vehicle. 6. Fill the transmission with Dexron III fluid. 7. Connect the negative battery cable. 8. Inspect the transmission oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3220 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3221 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3227 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3228 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3233 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3234 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3235 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3236 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3242 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3243 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3244 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3245 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3246 Case: Service and Repair Case Side Cover Replacement Removal Procedure 1. Remove the battery. 2. Remove the air inlet duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3247 3. Disconnect the shift cable from the PNP switch. 4. Remove the shift cable bracket 5. Remove the PNP switch. 6. Remove the transmission upper side cover bolts. 7. Install the engine support fixture. 8. Raise the vehicle. 9. Remove the left front tire and wheel. 10. Remove the left inner fender liner. 11. Separate the left ball joint from the steering knuckle. 12. Remove the wheel drive shaft from the transmission. 13. Remove the power steering gear mounting bolts. 14. Remove the front suspension cross member bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3248 15. Remove the transmission mount. 16. Lower the vehicle. 17. Lower the engine with the engine support fixture. 18. Raise the vehicle. 19. Remove the transmission side cover lower bolts. 20. Remove the transmission side cover. Installation Procedure 1. Install the transmission side cover. Notice: Refer to Fastener Notice in Service Precautions 2. Hand start the transmission side cover lower bolts. Tighten the side cover bolts and stud to 28 Nm (22 ft. lbs.). 3. Lower the vehicle. 4. Raise the engine with the engine support fixture. 5. Raise the vehicle. 6. Install the transmission mount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3249 7. Install the front suspension cross member bolts.. 8. Install the power steering gear mounting bolts. 9. Install the wheel drive shaft to the transmission. 10. Connect the left ball joint to the steering knuckle. 11. Install the left inner fender liner. 12. Install the left front tire and wheel. 13. Lower the vehicle. 14. Remove the engine support fixture. 15. Hand start the transmission side cover upper bolts. Tighten the side cover bolts and stud to 28 Nm (22 ft. lbs.). 16. Install the PNP switch. 17. Install the shift cable bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 3250 18. Connect the shift cable from the PNP switch. 19. Install the air inlet duct. 20. Install the battery. 21. Fill the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 3259 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3264 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3265 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-07-30-032E > Sep > 08 > A/T 4T65E Fluid Leaking From A/T Vent > Page 3275 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-033 > Aug > 04 > A/T 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-033 > Aug > 04 > A/T 4T65-E, No Reverse Hot/Slips in Reverse > Page 3280 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-033 > Aug > 04 > A/T 4T65-E, No Reverse Hot/Slips in Reverse > Page 3281 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation Fuel Pump Pickup Filter: All Technical Service Bulletins Fuel System - No Start/Low Power/Hesitation Bulletin No.: 05-06-04-026A Date: April 27, 2005 TECHNICAL Subject: Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure (Test Fuel Pressure and Replace Fuel Pump Module Strainer) Models: 2002-2003 Chevrolet Malibu 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire Supercede: This bulletin is being revised to add a additional step to retest the fuel pressure after the strainer is replaced. Please discard Corporate Bulletin Number 05-06-04-026 (Section 06 - Engine). Condition Some customers may comment that the vehicle hesitates, does not start, and/or has lack of power. Cause The vehicle may have low fuel pressure caused by a restricted fuel pump strainer. The current fuel pump has a 100 micron strainer. Correction Follow the service procedure below to test fuel pressure and replace the fuel strainer with a 200 micron strainer. Caution: ^ Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. ^ Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. Note: Clean the fuel system service cap and surrounding area to avoid possible contamination in the system. Important: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF the ignition. 2. Turn OFF all accessories. 3. Install fuel pressure gauge, J 34730-1A, or equivalent. Important: ^ The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. ^ DO NOT start the engine. 4. Command the fuel pump relay ON with a scan tool. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3287 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3288 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3289 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3295 5. Observe the fuel pressure gage with the fuel pump commanded ON. ^ If the fuel pressure IS between 345-414 kPa (50-60 psi), fuel system pressure is not the cause. Refer to the appropriate SI Document for additional diagnostic information. ^ If the fuel pressure IS LESS THEN 345-414 kPa (50-60 psi), continue with the next step. 6. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on model and year. 7. Flush the fuel tank with hot water. 8. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete. 9. Allow the tank to dry completely before reassembly. Refer to Fuel System Cleaning for additional information. Caution: The pot of the sending unit may have fuel in it. Use caution not to spill fuel on yourself while servicing the strainer. Note: Use care not to damage the fuel module pot when removing the old strainer. Damage to the pot may make it difficult or impossible to install the new strainer and/or make the module inoperative. 10. Insert the tip of a small screw driver between the strainer and the pot and push the screwdriver up slowly while rotating the screwdriver to pop off the strainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3296 11. Install the new strainer from kit, P/N 88967293, as shown above until you hear a positive click sound. 12. Double check that the strainer is installed properly and there is no damage to the pot before reinstalling the fuel module. Important: DO NOT reuse the old fuel pump module seal. 13. Remove the old fuel pump module seal from the fuel module. Important: The strainer kit, P/N 88967293, includes two new seals. It is critical that the same design seal be reinstalled that was removed. 14. Install the same design seal from kit, P/N 88967293, that was removed from the fuel pump module. 15. Reinstall the fuel pump module into the fuel tank. Refer to Fuel Pump Module Replacement in SI. Use the appropriate SI Document depending on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 05-06-04-026A > Apr > 05 > Fuel System - No Start/Low Power/Hesitation > Page 3297 model and year. 16. Retest the fuel pressure with fuel pressure gauge, J 34730-1A or equivalent, to ensure adequate fuel pressure after the strainer is installed. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 3306 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 3307 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 3317 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 3318 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3327 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3328 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 3329 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 6.5L (6.9 Qt) Overhaul ........................... .............................................................................................................................................................. ................... 9.0L (9.5 Qt) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3332 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 3333 Fluid - A/T: Service and Repair AUTOMATIC TRANSMISSION FLUID It is not necessary to check the transaxle fluid level. A transaxle fluid leak is the only reason for fluid loss. If a leak occurs have it repaired as soon as possible. You may also check your fluid level by following the Transmission Fluid Level and Condition Check procedure. See: Testing and Inspection/Component Tests and General Diagnostics Change both the fluid and filter every 50,000 miles (83 000 km) if the vehicle is mainly driven under one or more of these conditions: * In heavy city traffic where the outside temperature regularly reaches 90°F (32°C) or higher. * In hilly or mountainous terrain. * When doing frequent trailer towing. * Uses such as found in taxi, police or delivery service. If you do not use your vehicle under any of these conditions, the fluid and filter do not require changing. Notice: Use of automatic transaxle fluid labeled other than DEXRON-III may damage your vehicle, and the damages may not be covered by your warranty. Always use DEXRON-III labeled automatic transaxle fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement ^ Tools Required J 6125-1B Slide Hammer Adapter - J 23129 Universal Seal Remover Removal Procedure 1. Remove transaxle oil pan. 2. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 3. Check the oil filter seal for damage or wear. 4. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of petroleum jelly. 2. Install a new filter into the case. 3. Install transaxle oil pan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 3341 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 3342 Fluid Line/Hose: Service and Repair Automatic Transmission Oil Cooler Pipes Replacement Use only double-wrapped and use only brazed steel pipe meeting the GM specification 123M or equivalent if replacement of the transaxle oil cooler pipes are required. Ensure the pipe is double-flared. Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. 2. Position the drain pan. 3. Remove the transaxle oil cooler pipe at the transaxle. 4. Remove the transaxle oil cooler pipe fittings at the radiator. 5. Remove the transaxle oil cooler pipe clip bolt. 6. Remove the transaxle oil cooler pipes. Installation Procedure Important: The correct thread engagement is critical. Crossthreaded fittings can achieve proper tightness value and still leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Page 3343 1. Install the transaxle oil cooler pipes. Notice: Refer to Fastener Notice in Service Precautions 2. Install the transaxle oil cooler pipe clip bolt. Tighten the transaxle oil cooler pipe clip bolt to 4 Nm (27 inch lbs.). 3. Install the transaxle oil cooler pipe fittings at the radiator. Tighten the transaxle oil cooler pipe fittings to 45 Nm (33 ft. lbs.). 4. Install the transaxle oil cooler hoses to the pipes. 5. Lower the vehicle. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 6. Adjust the transmission fluid level. 7. Inspect for proper completion of the repairs. 8. Inspect for fluid leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 3348 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Pan Magnet Upgrade > Page 3349 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 3350 Fluid Pan: Specifications Oil Pan to Case ................................................................................................................................... ....................................................... 10 N-m (89 in.lb) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 3351 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise the vehicle. Support the vehicle. 2. Place the drain pan under the transaxle oil pan. Notice: When removing the oil pan bolts, be careful not to damage the oil pan sealing surfaces. Such damage may result in oil leaks in this area. 3. Remove the oil pan bolts from only the front and the sides. 4. Loosen the rear oil pan bolts about 4 turns. 5. Lightly tap the oil pan with a rubber mallet or pry in order to allow the fluid to drain. 6. Remove the remaining oil pan bolts. 7. Remove the oil pan. 8. Remove the oil pan gasket. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Technical Service Bulletins > Page 3352 1. Clean and inspect the oil pan for dents or damage. Dry the oil pan before installation. 2. Install the oil pan gasket. Use a new gasket if the sealing ribs are damaged. 3. Install the oil pan. Replace the bottom pan it damaged. Notice: Refer to Fastener Notice in Service Precautions 4. Install the oil pan attaching bolts. Tighten the bolts to 14 Nm (124 inch lbs.). 5. Lower the vehicle. 6. Fill the transmission. 7. Inspect the transmission fluid level. 8. Inspect the oil pan gasket for leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3356 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3357 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3362 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3363 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3364 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3365 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3366 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3367 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Diagrams Shift Indicator Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Diagrams > Page 3375 Shift Indicator: Description and Operation SHIFT INDICATOR The IPC illuminates the shift indicator when the PCM determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Maintenance Indicator A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 3383 Output Shaft: Service and Repair Output Axle Shaft Sleeve and Seal Replacement ^ Tools Required J 41227 Output Shaft Sleeve Remover - J 41228 Stub Shaft Sleeve Installer Removal Procedure 1. Raise the vehicle. Support the vehicle. 2. Remove the drive axle assembly. 3. Remove the snap ring from axle. 4. Remove the stub axle seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 3384 5. Use the J 41227 to remove the sleeve from the stub axle. Installation Procedure Important: 1. The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. 2. Use the J 41228 to install a new sleeve on the stub axle shaft. Ensure that the collet is located in the snap ring groove when installing. 3. Install the new stub axle seal. 4. Install one new snap ring on the output shaft. 5. Install the drive axle assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 3385 6. Lower the vehicle. 7. Inspect the output axle shaft sleeve for leaks. 8. Inspect the transmission oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Technical Service Bulletins > A/T - 4T65-E Final Drive Assembly Precaution Output Shaft Bearing/Bushing: Technical Service Bulletins A/T - 4T65-E Final Drive Assembly Precaution Bulletin No.: 04-07-30-030 Date: July 02, 2004 INFORMATION Subject: Using Caution When Servicing Final Drive Unit on 4T65-E Transaxles To Insure Internal Gear Thrust Bearing (695) is Properly Seated/Located Models: 2001-2005 GM Passenger Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) When servicing a final drive unit on a 4T65-E transaxle, use extreme caution to ensure that the internal gear thrust bearing (695) is properly seated/located. It has been found that after servicing a final drive unit on 4T65-E transaxles, the internal gear thrust bearing (695) was not properly seated/located causing internal damage and a repeat repair. Use a generous amount of Transgel J 36850 when installing the internal gear thrust bearing (695) to the park gear (696) to ensure the internal thrust bearing (695) will retain its proper position during assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Service and Repair Parking Lock Cable: Service and Repair Park Lock Cable Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the console. 3. Remove the knee bolster. 4. Loosen the lower steering column bracket bolts. 5. Lower the steering column. 6. Place the transmission shift lever in the PARK position. Important: Do not proceed to the next step with the key in any position other than the RUN position. 7. Turn the ignition key to the RUN position. 8. Insert a screwdriver blade into the slot provided in the ignition switch inhibitor. 9. Depress the cable latch. Pull the control cable from the inhibitor. 10. Push the cable connector lock button at the shifter base to the up position. 11. Unsnap the cable from the park/lock lever pin. 12. Depress the two cable latches. Remove the control cable latches from the automatic transmission control. 13. Remove the control cable clips. Installation Procedure Important: When installing a new park/lock cable, keep the shipping cover gauge attached until you are instructed to detach it. The shipping cover gauge will aid in the proper positioning of the cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Service and Repair > Page 3393 1. Ensure that the cable lock button is in the up position. Place the shift lever in the PARK position. 2. Snap the control cable connector into the automatic transmission control. 3. Place the ignition key in the RUN position. Important: Do not insert the cable with the key in any position other than the RUN position. 4. Snap the control cable into the inhibitor housing until the snap lock is seated. 5. Remove the shipping cover gauge. 6. Turn the key to the LOCK position. 7. Snap the control cable end onto the shift park/lock lever pin. 8. Push the cable connector hose forward in order to remove any slack. 9. With no load applied to the connector nose, snap the cable connector lock button down. Important: Inspect for proper operation of the park/lock control cable before installing the steering column to the instrument panel. 10. Raise and connect the steering column. 11. Tighten the lower steering column bracket bolts. 12. Install the knee bolster. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Service and Repair > Page 3394 13. Install the console. 14. Connect the negative battery cable. Inspection Procedure Important: ^ There must be no gap between the metal terminal stop and the protruding end of the white plastic collar. If there is a gap between the terminal stop and the collar, adjust the position of the park lock cable. ^ The white plastic collar must be flush or recessed about 1 mm (0.04 inch) within the ignition park lock housing. If the white plastic collar is not in the proper location, adjust the position of the park lock cable. 1. Ensure that the terminal stop on the column end of the park/lock cable is touching the white collar that protrudes from the ignition switch. Complete the following steps in order to inspect: 1.1. Turn the column lock cylinder to the LOCK position. 1.2. Place the floor shift into the PARK position. 1.3. Verify the correct position of the terminal stop. 2. Ensure that the white plastic collar travel does not exceed 1.5 mm (0.06 inch). In order to inspect the white plastic collar travel, complete the following steps: 2.1. Ensure that the column lock cylinder remains in the Lock position. 2.2. Ensure that the floor shift lever remains in the PARK position. 2.3. Gently depress the park/lock button on the floor shift lever until resistance is felt. 2.4. Inspect that the white plastic collar travels no more than 1.5 mm (0.06 inch). The floor shift lever must not come out of PARK. 3. With the column lock cylinder On, verity proper movement of the floor shift lever through all of the gear selections. 4. While moving the floor shift lever through all of the drive gears, verify that the column lock cylinder cannot be turned to the Lock position. 5. Ensure that the key can be removed with the column lock cylinder in the Lock position and the floor shift lever in the PARK position. Important: There are 5 inspections that verify proper installation. The installation must pass all 5 tests. 6. Adjust the park/lock cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3402 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3403 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 3412 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 3418 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3423 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3424 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3425 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3426 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3432 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3433 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3434 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 3435 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3436 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3437 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3438 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement Seals and Gaskets: Service and Repair Oil Filter and Seal Replacement Oil Filter and Seal Replacement ^ Tools Required J 6125-1B Slide Hammer Adapter - J 23129 Universal Seal Remover Removal Procedure 1. Remove transaxle oil pan. 2. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 3. Check the oil filter seal for damage or wear. 4. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of petroleum jelly. 2. Install a new filter into the case. 3. Install transaxle oil pan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3441 Seals and Gaskets: Service and Repair Oil Cooler Pipe Seals Replacement Oil Cooler Pipe Seals Replacement ^ Tools Required J 41239-10 Cooler Line Seal Remover. - J 41239-1 Cooler Line Seal Installer. Removal Procedure Caution: Refer to Vehicle Lifting in Service Precautions. 1. Raise the vehicle. Support the vehicle. 2. Remove the transmission oil cooler pipes from the transmission. 3. Remove the cooler pipe bracket stud. 4. Remove the oil cooler pipe seals. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3442 1. Install the J 41239-1 on the transmission case using cooler pipe bracket stud hole. 2. Press the new seals in. Tighten the J 41239-1 until the seal bottoms out in the case bore. 3. Install the cooler pipe bracket stud. 4. Install the transmission oil cooler pipes. 5. Lower the vehicle. 6. Inspect the transmission fluid level. 7. Operate the engine for 2 or 3 minutes. 8. Inspect the transmission fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3443 Seals and Gaskets: Service and Repair Torque Converter, Turbine Shaft Seal Replacement Torque Converter, Turbine Shaft Seal Replacement Removal Procedure 1. Remove the transaxle assembly from the vehicle. 2. Remove the torque convertor assembly from the transmission. 3. Remove the torque convertor O-ring seal from the end of the turbine shaft. Use a screwdriver. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3444 1. Install a new torque convertor O-ring seal on the end of the turbine shaft. 2. Install the torque convertor onto the transmission. 3. Install the transaxle into the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3445 Seals and Gaskets: Service and Repair Case Side Cover Seal Replacement Case Side Cover Seal Replacement ^ Tools Required J 41227 Output Shaft Sleeve Remover - J 41228 Stub Shaft Sleeve Installer - J 41102 Axle Seal Installer Removal Procedure Caution: Refer to Vehicle Lifting. 1. Raise the vehicle. 2. Remove the drive axle assembly. 3. Use a medium screwdriver and a mallet in order to remove the case cover seal. 4. Remove the drive axle retaining clip from the output axle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3446 5. Use the J 41227 in order to remove the sleeve from the output axle shaft. 6. Clean and inspect the seal bore. 7. Use fine sand paper in order to remove any burrs or nicks. Clean the entire area after any sanding. Installation Procedure 1. Use the J 41102 and a mallet in order to install the new case cover seal. 2. Use the J 41228 in order to install a new sleeve on the output axle. Install the J 41228 so that the collar is in the snap ring groove. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3447 3. This step tests for low fluid level, which may cause slipping, and result in an incorrect gear ratio. 4. This step verifies that the correct gear ratios occur for commanded gears. 5. This step tests for low line pressure. 3. Install the axle shaft retaining clip onto the output axle. 4. Install the drive axle assembly. 5. Lower the vehicle. 6. Inspect the shaft sleeve for leaks. 7. Inspect the transmission oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3448 Seals and Gaskets: Service and Repair Oil Filter and Seal Replacement Oil Filter and Seal Replacement ^ Tools Required J 6125-1B Slide Hammer Adapter - J 23129 Universal Seal Remover Removal Procedure 1. Remove transaxle oil pan. 2. Remove the oil filter. Use a long screwdriver in order to pry the oil filter neck out of the seal. 3. Check the oil filter seal for damage or wear. 4. As needed, remove the seal using the J 6125-1B and the J 23129. Installation Procedure 1. Install a new seal, as needed. Before installing, coat the new seal with a small amount of petroleum jelly. 2. Install a new filter into the case. 3. Install transaxle oil pan. Oil Cooler Pipe Seals Replacement Oil Cooler Pipe Seals Replacement ^ Tools Required J 41239-10 Cooler Line Seal Remover. - J 41239-1 Cooler Line Seal Installer. Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3449 Caution: Refer to Vehicle Lifting in Service Precautions. 1. Raise the vehicle. Support the vehicle. 2. Remove the transmission oil cooler pipes from the transmission. 3. Remove the cooler pipe bracket stud. 4. Remove the oil cooler pipe seals. Installation Procedure 1. Install the J 41239-1 on the transmission case using cooler pipe bracket stud hole. 2. Press the new seals in. Tighten the J 41239-1 until the seal bottoms out in the case bore. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3450 3. Install the cooler pipe bracket stud. 4. Install the transmission oil cooler pipes. 5. Lower the vehicle. 6. Inspect the transmission fluid level. 7. Operate the engine for 2 or 3 minutes. 8. Inspect the transmission fluid level. Torque Converter, Turbine Shaft Seal Replacement Torque Converter, Turbine Shaft Seal Replacement Removal Procedure 1. Remove the transaxle assembly from the vehicle. 2. Remove the torque convertor assembly from the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3451 3. Remove the torque convertor O-ring seal from the end of the turbine shaft. Use a screwdriver. Installation Procedure 1. Install a new torque convertor O-ring seal on the end of the turbine shaft. 2. Install the torque convertor onto the transmission. 3. Install the transaxle into the vehicle. Case Side Cover Seal Replacement Case Side Cover Seal Replacement ^ Tools Required J 41227 Output Shaft Sleeve Remover - J 41228 Stub Shaft Sleeve Installer - J 41102 Axle Seal Installer Removal Procedure Caution: Refer to Vehicle Lifting. 1. Raise the vehicle. 2. Remove the drive axle assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3452 3. Use a medium screwdriver and a mallet in order to remove the case cover seal. 4. Remove the drive axle retaining clip from the output axle. 5. Use the J 41227 in order to remove the sleeve from the output axle shaft. 6. Clean and inspect the seal bore. 7. Use fine sand paper in order to remove any burrs or nicks. Clean the entire area after any sanding. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3453 1. Use the J 41102 and a mallet in order to install the new case cover seal. 2. Use the J 41228 in order to install a new sleeve on the output axle. Install the J 41228 so that the collar is in the snap ring groove. 3. This step tests for low fluid level, which may cause slipping, and result in an incorrect gear ratio. 4. This step verifies that the correct gear ratios occur for commanded gears. 5. This step tests for low line pressure. 3. Install the axle shaft retaining clip onto the output axle. 4. Install the drive axle assembly. 5. Lower the vehicle. 6. Inspect the shaft sleeve for leaks. 7. Inspect the transmission oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3454 Stub Axle Shaft Sleeve and Seal Replacement Stub Axle Shaft Sleeve and Seal Replacement ^ Tools Required J 38863 Gear Installer Remover - J 6125-1B Slide Hammer - J 23129 Axle Boot Remover - J 41102 Axle Seal Installer Removal Procedure 1. Remove the drive axle assembly. Important: Do not damage the seal bore or the sleeve assembly. Fluid leaks may result. 2. Remove the snap ring from the stub axle shaft. Discard the snap ring. Do not reuse. 3. Remove the stub axle shaft from the transaxle. Use the J 6125-1B and the J 38368. 4. Pull lightly on the shaft. Rotate the shaft until the output shaft snap ring at the differential seals in the taper on the differential side gear. 5. Remove inner snap ring. 6. Remove the right hand axle seal from the transaxle. Use the J 23129 and the J 6125-1B. Installation Procedure Important: 1. The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. 2. Install the new seal. Use the J 41102. Lubricate the seal lip with a light wipe of transmission oil. Important: Carefully guide the stub axle shaft past the lip seal. Do not allow the shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3455 3. Install the two new snap rings on the stub shaft. 4. Install the stub shaft into the transmission. Use a mallet. 5. Install the drive axle assembly. 6. Lower the vehicle. 7. Inspect the oil level. 8. Inspect the shaft and the seal for leaks. Output Axle Shaft Sleeve and Seal Replacement Output Axle Shaft Sleeve and Seal Replacement ^ Tools Required J 41227 Output Shaft Sleeve Remover - J 41228 Stub Shaft Sleeve Installer Removal Procedure 1. Raise the vehicle. Support the vehicle. 2. Remove the drive axle assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3456 3. Remove the snap ring from axle. 4. Remove the stub axle seal. 5. Use the J 41227 to remove the sleeve from the stub axle. Installation Procedure Important: 1. The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Oil Filter and Seal Replacement > Page 3457 2. Use the J 41228 to install a new sleeve on the stub axle shaft. Ensure that the collet is located in the snap ring groove when installing. 3. Install the new stub axle seal. 4. Install one new snap ring on the output shaft. 5. Install the drive axle assembly. 6. Lower the vehicle. 7. Inspect the output axle shaft sleeve for leaks. 8. Inspect the transmission oil level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3465 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3466 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3470 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3471 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3475 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3476 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Under Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3484 Automatic Transmission Shift Lock Control Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 3488 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 3491 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in earn of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Service and Repair Shift Linkage: Service and Repair Floor Shift Control Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the automatic transmission control lever handle retainer. 3. Remove the automatic transmission control lever handle. 4. Remove the console. 5. Remove the range select lever cable from the automatic transmission control. 6. Position aside the park lock cable. 7. Remove the electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Service and Repair > Page 3495 8. Remove the automatic transmission control nuts. 9. Remove the automatic transmission control. Installation Procedure 1. Install the automatic transmission control. Notice: Refer to Fastener Notice in Service Precautions 2. Install the automatic transmission control nuts. Tighten the nuts to 25 Nm (18 ft. lbs.). 3. Install the electrical connector. 4. Install the park lock cable. 5. Install the range select lever cable to the automatic transmission control. 6. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Service and Repair > Page 3496 7. Install the automatic transmission control lever handle. 8. Instal the automatic transmission control lever handle retainer. 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 3505 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 3506 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 3512 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 3513 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Gear: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition Spark Plug: All Technical Service Bulletins Recall - Spark Plug Misfire Condition Product Emission - Loose Spark Plug Center Wire # 03042 - (09/24/2003) 03042 - Loose Spark Plug Center Wire ***Dealer Inventory Vehicles Only*** 2003-2004 Chevrolet TrailBlazer, TrailBlazer EXT 2003-2004 GMC Envoy, Envoy XL 2004 Oldsmobile Bravada Equipped with 4.2L L6 Engine (LL8) 2004 Chevrolet Cavalier, Classic 2004 Oldsmobile Alero 2004 Pontiac Grand Am, Sunfire Equipped with 2.2L L4 Engine (L61) THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003. Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness. Correction Dealers are to inspect the spark plug(s) and replace them if necessary. Vehicles Involved Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Gear: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3519 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Gear: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3520 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Gear: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3526 spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC). Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order. Service Procedure Important The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information. 1. If the vehicle has an L6 engine, remove the # 2 spark plug. 2. If the vehicle has an L4 engine, remove the # 1 spark plug. Important In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code. 3. Inspect the spark plug for a date code. Refer to the illustration above. 203 = Date Code 3 = Year 1 = Line 1 = Shift. ^ If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156. ^ If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs. 4. Install the GM Recall Identification Label. Recall Identification Label Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. For US and IPC When installing the Recall Identification Label be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office. For Canada Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sun Gear: > 03042 > Sep > 03 > Recall - Spark Plug Misfire Condition > Page 3527 Additional Recall Identification Labels for Canadian dealers can be obtained from DGN. Claim Information Submit a Product Recall claim with the information shown. Refer to the General Motors WINS claim Processing Manual for details on Product Recall claim Submission. Customer Notification There will be no customer notification. This recall is for vehicles in dealer inventory only. Dealer Recall Responsibility -- ALL All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall through November 30, 2003. In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 3532 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 3537 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3541 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3542 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3547 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3548 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3549 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3550 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3551 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 3552 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3553 Transmission Cooler: Description and Operation Transmission Oil Cooler The transmission oil cooler is a heat exchanger. It is located inside the right side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator. The transmission oil pump, pumps the fluid through the transmission oil cooler line to the transmission oil cooler. The fluid then flows through the cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the transmission oil cooler return line, to the transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Automatic Transmission Mount Replacement Removal Procedure Important: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Use a jack or a utility stand to raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the mount. 2. Inspect the transmission/transaxle mount. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: ^ The rubber surface is covered with cracks. ^ The rubber is separated from the metal plate of the mount. ^ The rubber is split through the center. 3. If there is movement between the metal plate of the transmission/transaxle mount and the transmission, tighten the transmission mount fasteners to the correct tightening specification. 1. Raise and support the vehicle. 2. Remove the left front wheel and tire assembly. 3. Remove the left front fender liner. 4. Install a jackstand and a block of wood to support the transaxle. 5. Remove the expansion bolt from the transmission mount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 3557 6. Remove the transmission mount bolts. 7. Remove the mount. Installation Procedure 1. Transfer the mount bracket to the new mount. 2. Position the mount and start the bolts into the threads. Notice: Refer to Fastener Notice in Service Precautions 3. Tighten the mount bolts. Tighten the bolts to 66 Nm (41 ft. lbs.). 4. Install the mount expansion bolt. Tighten the bolt to 55 Nm (41 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 3558 5. Remove the jackstand and the wood block. 6. install the left fender liner. 7. Install the left tire and wheel assembly 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3562 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3563 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3567 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3568 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: Customer Interest A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3580 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3581 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3582 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3583 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3584 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3585 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3590 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3591 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3596 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3597 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Valve Body: All Technical Service Bulletins A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 Bulletin No.: 07-07-30-025 Date: October 01, 2007 INFORMATION Subject: Information On 4T40-E (MN4) and 4T45-E (MN5) Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0742, P0751, P0752, P0756, P0757, P1811, Harsh Shifts, Slips, No Drive, No Reverse Models: 1997-2005 Chevrolet Cavalier 1997-2007 Chevrolet Malibu 2005-2007 Chevrolet Cobalt 2006-2007 Chevrolet Malibu Maxx, HHR 1997-1998 Oldsmobile Cutlass 1999-2004 Oldsmobile Alero 1997-2005 Pontiac Sunfire 1999-2005 Pontiac Grand Am 2005-2006 Pontiac Pursuit (Canada Only) 2005-2007 Pontiac G6 2007 Pontiac GS 2000-2005 Saturn L-Series 2005-2007 Saturn ION, VUE 2007 Saturn Aura with Hydra-Matic(R) 4T40-E (RPO MN4) and 4T45-E (RPO MN5) Automatic Transmission The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. The service bulletin will also provide additional service information documents that are related to the 4L6x transmission family. Related Service Documents PIP 3253B - No Move Drive or Reverse 02-07-30-039F - Firm Transmission Shifts 02-07-30-050 - Engineering Change Valve Body If valve body cleaning is not required, Do Not disassembly bores unless it is necessary to verify movement of valves. Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning valve and bore, then replace valve body. Describe restricted valve on repair order. Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove valve and burr, then inspect movement in the valve's normal position. If no other debris or restrictions are found, then reassemble valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3607 positive identification and location of individual parts: Valve Body Spring and Bore Plug Chart (Metric) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3608 Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3609 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3610 Left Side Control Valve Body Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3611 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 07-07-30-025 > Oct > 07 > A/T - DTC's P0741/P0751/P0752/P0756/P0757/P1811 > Page 3612 Right Side Control Valve Body Assembly Control Valve Body Assembly Chart, Valve Springs and Bore Plugs Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3617 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 3618 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3623 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 3624 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3630 Valve Body: Service and Repair Control Valve Body Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the bolts (9, 12 and 16) from the control valve body assembly (18). 3. Remove the control valve body assembly (18). 4. Remove and discard the valve body to spacer plate gasket (22). Installation Procedure 1. Install the control valve body to spacer plate gasket (22) onto the spacer plate (23). 2. Install the control valve body assembly (18) onto the gasket (22). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3631 3. Inspect the TFP switch assembly (13) in order to verify the condition and correct location of the seven pressure switch O-rings. 4. If necessary replace the pressure switch O-rings. 5. Install the TFP switch assembly (13) onto the control valve body assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 3632 6. Install the eighteen control valve body assembly bolts. Notice: Refer to Fastener Notice in Service Precautions 7. Hand start the bolts. Tighten the bolts to 14 Nm (124 inch lbs.). 8. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: Customer Interest A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 3641 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: Customer Interest A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 3646 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 3647 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: All Technical Service Bulletins A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 3653 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: All Technical Service Bulletins A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 3658 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 3659 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 3660 Wiring Harness: Service and Repair Wiring Harness Replacement Removal Tools Required ^ J41101 Pass-Through Connector Remover 1. Remove the transmission side cover. 2. Remove the control valve body. 3. Push the J41101 onto the pass-through connector from the outside of the transmission case in order to compress the pass-through connector,s retaining tabs. 4. With the retaining tabs compressed, use a screw driver in order to remove the pass-through 5. Remove the wiring harness (11) Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 3661 Connect the wiring harness assembly to the following components: ^ The TFP switch assembly (13) ^ The pressure control solenoid (312) (red Connector) Important The 1-2 shift solenoids wires are red and light green. The 2-3 shift solenoid wires are red and yellow. ^ The 1-2 shift solenoid (305) (white connector) ^ The 2-3 Shift Solenoids (305) (White connectors) ^ The TCC solenoid (335) ^ Install the control valve body. ^ Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair Clutch Drive Plate and Clutch Driven Plate ^ Tools Required J 29074 Clutch Alignment Arbor Removal Procedure 1. Remove the transmission. 2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. 3. Remove the clutch cover and the clutch disc. Installation Procedure 1. Align the Heavy Side of the flywheel assembly (stamped with an X), with the clutch cover Light Side (marked with paint). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3666 2. Install the J 29074 in order to support the clutch cover to the flywheel assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the clutch cover to flywheel bolts. 3.1. Follow the tightening sequence. Tighten the bolts to 24 Nm (18 ft. lbs.). 3.2. Tighten the bolts to specifications. 4. Remove the J 29074. 5. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 6. Install the transmission. 7. Bleed the hydraulic system. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID Hydraulic Clutch Fluid (GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Remove the clutch master cylinder pushrod from the clutch pedal. 2. Remove the master cylinder retaining nuts at the front of the dash. 3. Remove the remote reservoir. 4. Disconnect the clutch actuator cylinder line. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 3674 5. Remove the clutch master cylinder assembly from the clutch pedal assembly. Installation Procedure 1. Install the clutch master cylinder assembly to the clutch pedal assembly. 2. Connect the clutch actuator cylinder line. 3. Install the remote reservoir. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 3675 4. Install the master cylinder retaining nuts at the front of the dash. Tighten the nuts evenly to 21 Nm (15 ft. lbs.). 5. Install the pushrod to the clutch pedal. 6. Bleed the hydraulic system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement Removal Procedure 1. Disconnect the clutch actuator cylinder line. 2. Remove the transmission. 3. Remove the clutch actuator cylinder bolts from the transmission. 4. Remove the following components from the transmission: ^ The upper bolt ^ The clutch actuator cylinder Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 3679 1. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 2. Install the following components to the transmission: ^ The clutch actuator cylinder ^ The bolts 3. Install the upper line release bolt. 4. Install the transmission. 5. Connect the clutch actuator cylinder line. 6. Bleed the hydraulic system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released Hydraulic Hose: Customer Interest M/T - Grinding Noise When Clutch is Released Bulletin No.: 03-07-31-005 Date: October 30, 2003 TECHNICAL Subject: Grind Noise from Manual Transmission When Clutch Is Released (Replace Clutch Actuator Pipe) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with Manual Transmission (RPO M86 or M94) VIN Breakpoints Condition Some customers may comment on a grind noise from the transmission when the clutch is released all the way, clutch pedal pushed all the way to the floor. Cause A over travel condition of the clutch could cause a clutch finger to clutch disk interference that may emit a grinding type noise transmitted through the clutch actuator pipe to the clutch pedal to the driver's foot. Correction A new clutch actuator pipe which includes a damper has been developed to reduce the vibration and noise. Replace the clutch actuator pipe using the procedure and part numbers listed below. Important: DO NOT REPLACE the following clutch components. They WILL NOT correct this condition. ^ P/N 90537283 ^ P/N 22629291 ^ P/N 22629292 ^ P/N 12578064 ^ P/N 12578156 1. Remove the air cleaner outlet duct. 2. Disconnect the battery cables and remove the battery. 3. Remove the relay center push in retainer. 4. Disconnect the relay battery feed cable from the upper air cleaner cover retaining clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released > Page 3688 5. Position the relay center away from the air cleaner assembly. 6. Remove the push in retainer from the air cleaner assembly to the battery tray. 7. Remove the air cleaner assembly from the vehicle. 8. Remove the clip and disconnect the clutch actuator pipe from the master cylinder. 9. Remove the clip and disconnect the clutch actuator pipe from the actuator. 10. Remove the old clutch actuator pipe. 11. Install the new clutch actuator pipe, P/N 12580748, into position. The actuator pipe includes the entire master cylinder. 12. Connect the new clutch actuator pipe to the master cylinder and install the clip. 13. Connect the new clutch actuator pipe to the actuator and install the clip. 14. Install retaining bracket, P/N 12588319, with bolt, P/N 22598028, and nut, P/N 11514596, as shown above. Tighten Tighten the nut and bolt to 10 Nm (2.25 lb ft). 15. Slide the pin part of the air cleaner assembly into the bracket hole on the left strut tower. 16. Position and install the air cleaner inlet over the resonator neck. 17. Install the push in retainer from the air cleaner to the battery tray. 18. Install the relay center and the push in retainer. 19. Connect the relay battery feed cable into the upper air cleaner cover retaining clips. 20. Install the battery. 21. Install the air cleaner outlet duct. 22. Bleed the hydraulic clutch system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > Customer Interest for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released > Page 3689 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released Hydraulic Hose: All Technical Service Bulletins M/T - Grinding Noise When Clutch is Released Bulletin No.: 03-07-31-005 Date: October 30, 2003 TECHNICAL Subject: Grind Noise from Manual Transmission When Clutch Is Released (Replace Clutch Actuator Pipe) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with Manual Transmission (RPO M86 or M94) VIN Breakpoints Condition Some customers may comment on a grind noise from the transmission when the clutch is released all the way, clutch pedal pushed all the way to the floor. Cause A over travel condition of the clutch could cause a clutch finger to clutch disk interference that may emit a grinding type noise transmitted through the clutch actuator pipe to the clutch pedal to the driver's foot. Correction A new clutch actuator pipe which includes a damper has been developed to reduce the vibration and noise. Replace the clutch actuator pipe using the procedure and part numbers listed below. Important: DO NOT REPLACE the following clutch components. They WILL NOT correct this condition. ^ P/N 90537283 ^ P/N 22629291 ^ P/N 22629292 ^ P/N 12578064 ^ P/N 12578156 1. Remove the air cleaner outlet duct. 2. Disconnect the battery cables and remove the battery. 3. Remove the relay center push in retainer. 4. Disconnect the relay battery feed cable from the upper air cleaner cover retaining clips. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released > Page 3695 5. Position the relay center away from the air cleaner assembly. 6. Remove the push in retainer from the air cleaner assembly to the battery tray. 7. Remove the air cleaner assembly from the vehicle. 8. Remove the clip and disconnect the clutch actuator pipe from the master cylinder. 9. Remove the clip and disconnect the clutch actuator pipe from the actuator. 10. Remove the old clutch actuator pipe. 11. Install the new clutch actuator pipe, P/N 12580748, into position. The actuator pipe includes the entire master cylinder. 12. Connect the new clutch actuator pipe to the master cylinder and install the clip. 13. Connect the new clutch actuator pipe to the actuator and install the clip. 14. Install retaining bracket, P/N 12588319, with bolt, P/N 22598028, and nut, P/N 11514596, as shown above. Tighten Tighten the nut and bolt to 10 Nm (2.25 lb ft). 15. Slide the pin part of the air cleaner assembly into the bracket hole on the left strut tower. 16. Position and install the air cleaner inlet over the resonator neck. 17. Install the push in retainer from the air cleaner to the battery tray. 18. Install the relay center and the push in retainer. 19. Connect the relay battery feed cable into the upper air cleaner cover retaining clips. 20. Install the battery. 21. Install the air cleaner outlet duct. 22. Bleed the hydraulic clutch system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hydraulic Hose: > 03-07-31-005 > Oct > 03 > M/T - Grinding Noise When Clutch is Released > Page 3696 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure Important: Service the clutch pedal and bracket as an assembly. 1. Remove the clutch master cylinder pushrod from the clutch pedal. 2. Disconnect the clutch position and clutch cruise control switches. 3. Remove the clutch cruise control switch from the bracket. 4. Remove the instrument panel support beam. 5. Remove the instrument panel support beam bracket bolt. 6. Remove the clutch pedal and bracket mounting nuts. 7. Remove the clutch pedal and bracket assembly. Installation Procedure 1. Install the clutch pedal and bracket assembly. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 3700 2. Install the clutch pedal and bracket mounting nuts. Start with the lower nuts, tighten the nuts to 21 Nm (15 ft. lbs.). 3. Install the instrument support bracket bolt. 4. Install the instrument panel support beam. 5. Install the clutch master cylinder pushrod bushing on the pedal. Lubricate the bushing. 6. Install the clutch master cylinder pushrod to the clutch pedal. 7. Install the cruise control switch. 8. Connect the following components: ^ The cruise control switch ^ The clutch position switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications clutch cover to flywheel bolts ............................................................................................................... .................................................... 24 Nm (18 ft. lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3704 Pressure Plate: Service and Repair Clutch Drive Plate and Clutch Driven Plate ^ Tools Required J 29074 Clutch Alignment Arbor Removal Procedure 1. Remove the transmission. 2. Remove the clutch cover bolts one turn at a time, until spring pressure is relieved. 3. Remove the clutch cover and the clutch disc. Installation Procedure 1. Align the Heavy Side of the flywheel assembly (stamped with an X), with the clutch cover Light Side (marked with paint). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 3705 2. Install the J 29074 in order to support the clutch cover to the flywheel assembly. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the clutch cover to flywheel bolts. 3.1. Follow the tightening sequence. Tighten the bolts to 24 Nm (18 ft. lbs.). 3.2. Tighten the bolts to specifications. 4. Remove the J 29074. 5. Lubricate the inside diameter of the bearing with GM P/N 12345777, or equivalent. 6. Install the transmission. 7. Bleed the hydraulic system. 8. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) ^ Tools Required J 35910 Drive Axle Seal Clamp Pliers - J 35566 Drive Axle Seal Clamp Pliers - J 8039-A Snap Ring Pliers Disassembly Procedure Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 1. Remove the small seal retaining clamp from the halfshaft bar (3) with a side cutter. Discard the small seal retaining clamp. 2. Remove the large seal retaining clamp from the inboard joint with a side cutter. Discard the large seal retaining clamp. 3. Separate the inboard seal from the trilobal tripod bushing (2) at large diameter. 4. Slide seal away from joint along halfshaft bar (3) 5. Before removing the tripot spider assembly (3) from the halfshaft bar, perform the following procedure: Important: Never reuse the spacer ring (2). 6. Remove the spacer ring (2) from the end of the halfshaft bar using J 8039-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3717 7. Place a brass drift on the area of the tripot spider (1) next to the halfshaft bar (3). 8. Tap on the brass drift with the hammer. Important: Handle the tripot spider assembly (1) with care. 9. Remove the tripot spider assembly (1) from the halfshaft bar (3). 10. Remove the spacer ring (1) from the shoulder of the halfshaft bar using J 8039-A. Discard ring. 11. Remove and discard the trilobal tripot bushing from the housing. 12. Clean the following items thoroughly with cleaning solvent. Removing all traces of old grease and any contaminates. ^ The tripot balls ^ The needle rollers ^ The housing 13. Dry all the parts. 14. Remove and discard the seal from the halfshaft bar. 15. Inspect the following parts for damage or wear: ^ The spider assembly (3) ^ The housing ^ The tripot balls ^ The needle rollers Assembly Procedure 1. Install the new small seal retaining clamp on the neck of the seal. 2. Do not crimp the small seal retaining clamp. 3. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). 4. Slide the tripot seal and clamp onto the halfshaft bar, passing the seal grooves of the halfshaft bar toward the CV end of the halfshaft bar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3718 Important: Ensure that the spacer ring (1) is next to the shoulder of the halfshaft bar before installing the tripot spider (3). 5. Place the new spacer ring (1) next to the shoulder on the halfshaft bar. 6. Place the tripot spider assembly (3) onto the halfshaft bar. 7. Place the halfshaft assembly onto the arbor press. ^ The tripot spider assembly must be on the press plate. ^ The CV joint assembly must be under the press head. 8. Lower the arbor press head onto the CV joint assembly until the tripot spider is next to the spacer ring. Do not exceed 4,000 lbs (1,779 N) press load during assembly. 9. Remove the halfshaft assembly from the arbor press. 10. Place the new spacer ring (2) on the halfshaft bar groove at the end of the halfshaft bar. 11. Slide the tripot seal (7) to the corresponding groove on the halfshaft bar. 12. Crimp the small seal retaining clamp (6) using J 35910. a torque wrench (8), and a breaker bar (9). 13. Place approximately 1J- of the grease from the service kit in seal. Use the remainder to repack the housing. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3719 14. Install the new trilobal tripot bushing (2) to housing (1). Ensure the bushing (2) is flush with the face of the housing (1). 15. Slide the housing (1) over the spider assembly on the halfshaft bar (3). Important: The end of the inboard seal (4) must be next to the seal stop on the trilobal tripot bushing (2). 16. Position the large seal retaining clamp around the inboard seal (4). 17. Engage the inboard seal (4). Important: The halfshaft inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the halfshaft inboard seal (2) is not shaped correctly, carefully insert a thin, flat, blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the halfshaft inboard seal (2) properly by hand. Remove the thin, flat, blunt tool. 18. Position joint assembly at the proper vehicle dimension. ^ For vehicles with 2.2L engines and automatic transmissions, dimension a=90 mm (3.5 inch). ^ For all other vehicles, dimension a=115 mm (4.5 inch). Important: Align the following items while latching: ^ The halfshaft inboard seal (3) ^ The housing (1) ^ The large clamp (2) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3720 19. Latch the seal retaining clamp (2) using J3556, or crimp the seal retaining clamp (2) using J 35910 if the joint uses an eared clamp. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3721 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Seal Replacement (Trilobal) Wheel Drive Shaft Outer Joint and Seal Replacement (Trilobal) ^ Tools Required J 41398 CV Puller - J 2619-01 Slide Hammer Assembly - J 35910 Drive Axle Seal Clamp Pliers - J 8039-A Snap Ring Pliers Disassembly Procedure Important: Due to the helical splines on the halfshaft bar, disassembly and assembly of the joints will be difficult. Follow the instructions provided. 1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the large seal retaining clamp. 2. Remove the small seal retaining clamp from the halfshaft bar with a side cutter and discard. 3. Separate the CV joint seal from the CV joint race (2) at the large diameter. 4. Slide the seal away from the joint along the halfshaft bar. 5. Wipe the grease from the face of the CV joint inner race (1). 6. Before removing the CV joint assembly from the halfshaft bar, perform the following procedure: 6.1. Choose a reference mark (B) on the halfshaft bar. 6.2. Measure the distance between the reference mark (B) and the face of the CV joint inner race (1). Make a note of the measurement. The measurement is (A). 6.3. Mark the inboard side (toward the center of the halfshaft bar) of the CV joint inner race (1) as a reference. 6.4. Inspect the CV joint inner race/halfshaft bar interface for the presence of a retaining ring. If present, remove the retaining ring using J 8039-A 7. Clamp the halfshaft (1) into a vise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3722 8. Attach the J 41398 to the threaded area of the outer race (2). 9. Attach J2619-01 onto the outer end of the J 41398. 10. Use the J 2619-01 to remove the CV joint from the halfshaft bar. 11. Remove J2619-01 and J41398from the CV joint. Important: Never reuse the retaining ring. 12. Remove the retaining ring from the halfshaft bar. Discard the retaining ring. 13. Remove the CV joint seal (1) from the halfshaft bar. 14. Place a brass drift against the CV joint cage (1) 15. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 16. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 17. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 18. Repeat this process to remove all six of the balls. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3723 19. Pivot the CV joint cage (4) and the inner race 90 degrees to the centerline of the outer race (1) At the same time, align the cage windows with the lands of the outer race (2). 20. Lift out the cage (4) and the inner race. 21. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 22. Clean the inner and outer race assemblies, the CV joint cage and the chrome alloy balls thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 23. Dry all the parts. 24. Check the CV joint assembly for unusual wear, cracks, or other damage. 25. Replace any damaged parts. 26. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure 1. Put a light coat of grease from service kit on the ball grooves of the inner race and the outer race. 2. Hold the inner race 90 degrees to the centerline of the cage with the lands of the inner race (1) aligned with the windows of cage (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3724 3. Insert the inner race into the cage. 4. Hold the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows (3) with the lands of the outer race (2). Important: Ensure that the inner race is oriented the same as prior to disassembly. Use the reference mark placed earlier. 5. Install the cage and the inner race into outer race. 6. Place a brass drift against the CV joint cage (1). 7. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 8. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 9. Repeat this process to install all six of the balls. 10. Pack the CV joint with half of the grease supplied in the service kit. 11. Install the new small retaining clamp (2) on the neck of the seal (3). Do not crimp. 12. Clean the halfshaft bar (1). Use a wire brush to remove any rust in the seal mounting area (grooves). 13. Slide the CV joint seal (3) onto the halfshaft bar (1). Expose the reference mark (4) by sliding the CV joint seal (3) up the halfshaft bar (1) toward the tripot end. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3725 14. Position the large seal retaining clamp around the joint seal. 15. Place the new retaining ring onto the halfshaft bar. 16. While supporting the tripot assembly, place the halfshaft assembly onto the arbor press with the CV assembly under the press head. 17. Lower the arbor press head onto the CV joint assembly until the press cannot move any further This ensures that the retaining ring engages in the inner race. Do not exceed 4,000 lbs (1,779 N) press load during assembly. 18. Remove the halfshaft assembly from the arbor press. 19. Measure the distance between the reference mark on the halfshaft bar (B) and the face of the CV joint inner race (1). 20. Compare the mark with the measurement made before disassembly. 21. Repeat the previous four steps if the current measurement does not match the measurement made before disassembly. 22. Place the neck of the CV joint seal into the seal groove on the halfshaft bar. Notice: Refer to Fastener Notice in Service Precautions. Important: Check the clamp position during the crimping operation in order to ensure the clamp (1) is positioned correctly around the entire circumference. 23. Crimp the small retaining clamp (1) by using J 35910, a breaker bar, and a torque wrench. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement (Trilobal) > Page 3726 ^ Tighten the seal retaining clamp to 136 Nm (100 ft. lbs.). 24. Check the gap dimension. Continue tightening until the gap dimension is reached. 25. Place the remaining grease from the service kit inside the seal. 26. Measure approximately 17.5 mm (11/16 inch) up from the bottom edge of the CV outer joint assembly. 27. Slide the large diameter of the seal with the large seal retaining clamp in place over the outside of CV joint. Important: The CV joint seal must not be dimpled, stretched or out of shape in any way. If seal is not shaped correctly, equalize pressure in the seal and shape the seal properly by hand. 28. Locate the seal lip to the ridge of the CV outer joint assembly as measured in the previous step. 29. Crimp seal retaining clamp (1) with J35910, a breaker bar (3), and a torque wrench (2). ^ Tighten seal retaining clamp to 176 Nm (130 ft. lbs.). 30. Check the gap dimension. Continue tightening until the correct gap dimension is reached. Dimension a=3.9 mm (0.15 inch). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: All Technical Service Bulletins Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3745 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3746 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 3747 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection WHEEL BEARINGS DIAGNOSIS TOOLS REQUIRED J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Hub/Axle Flange and Wheel Stud Runout Inspection in Vibration Diagnosis and Correction. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. IMPORTANT:If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 in), replace the wheel bearing/hub. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension WHEEL BEARING/HUB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the drive axle nut. 4. Remove the brake rotor 5. Remove the mounting bolts (1) from the hub and bearing assembly (3). 6. Remove the hub and bearing assembly (1) from the steering knuckle (2) and drive axle shaft. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3753 1. Install the hub and bearing assembly (1) into the steering knuckle (2) and drive axle shaft. 2. Install the hub bearing mounting bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 95 N.m (70 lb ft). 3. Install the drive axle shaft nut. Tighten Tighten the drive axle shaft nut to 200 N.m (148 lb ft). 4. Install the brake rotor. 5. Install the tire and wheel assemblies. 6. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 3754 Wheel Bearing: Service and Repair Rear Suspension WHEEL BEARING/HUB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake drum. NOTE: Do not hammer on brake drum as damage to the bearing could result. 4. Disconnect the rear ABS wheel speed sensor wire connector. 5. Remove the hub and bearing assembly bolts 6. Remove the hub and bearing assembly from the axle. INSTALLATION PROCEDURE 1. Install the hub and bearing assembly to the axle in the axle assembly. NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the hub and bearing assembly bolts. Tighten Tighten the hub and bearing to axle bolts to 60 N.m (44 lb ft). 3. Connect the rear ABS wheel speed sensor wire connector. 4. Install the brake drum. 5. Install the tire and wheel assemblies. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Axle Nut ...................................................................................................................................... .................................................. 200 N.m (148 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate (AMT) Bolt First Pass ............................................................................................................................................. .................................................. 53 Nm (39 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 25 degrees Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams > Page 3770 Shift Indicator: Description and Operation SHIFT INDICATOR The IPC illuminates the shift indicator when the PCM determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .............................................................. 1.7L (1.8 Qt) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 3776 Fluid - M/T: Fluid Type Specifications Transmission Fluid .............................................................................................................................. .................................................................. Dexron III Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3777 Fluid - M/T: Testing and Inspection Transmission Fluid Checking Procedure Important: Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. 1. Raise and support the vehicle. 2. Remove the level check plug. 3. Verify that the fluid is up to the opening. 4. Perform the following procedure if no fluid is visible: 4.1. Lower the vehicle. 4.2. Add GM Dexron III Transmission Fluid, or equivalent, to the level check opening until the level check opening begins to leak fluid. 4.3. Raise and suitably support the vehicle. 5. Install the fluid level check plug. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 3778 Fluid - M/T: Service and Repair Transmission Fluid Checking Procedure Important: Inspect the fluid level only when the engine is off. Ensure the vehicle is level. The transaxle must be cold. 1. Raise and support the vehicle. 2. Remove the level check plug. 3. Verify that the fluid is up to the opening. 4. Perform the following procedure if no fluid is visible: 4.1. Lower the vehicle. 4.2. Add GM Dexron III Transmission Fluid, or equivalent, to the level check opening until the level check opening begins to leak fluid. 4.3. Raise and suitably support the vehicle. 5. Install the fluid level check plug. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Axle Shaft Oil Seal Replacement ^ Tools Required J 23129 Seal Remover - J 6125-B Slide Hammer - J 44335 Differential Bearing Race and Seal Installer - J 7079-2 Non-threaded Driver Handle Removal Procedure 1. Raise and suitably support the vehicle. 2. Remove the front wheel and tire assemblies. 3. Remove the wheel driveshaft. 4. Use the SA9133T in order to remove the seal. 5. Inspect the seal bore for nicks or for burrs. Clean the bore with a fine grade sandpaper, if necessary. Installation Procedure 1. Use the J 44385 and the J 7079-2 in order to install a new seal. Ensure that the seal is seated flush to the outer bore area. 2. Lubricate the seal with Dexron-III transmission fluid Saturn P/N 21019223. 3. Install the wheel driveshaft. 4. Install the front tire and wheel assemblies. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3786 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3787 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3788 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments Shift Cable: Adjustments Shift Cable Adjustment 1. Set the parking brake. 2. Remove the console. 3. Lift and unlock the shift cable retainers 4. Push the shifter neutral lock clip. Move the shifter slightly in order to center the lock clip. 5. Ensure that the transmission is in neutral. 6. Press and lock the shift cable retainers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3793 7. Pull the shifter neutral lock clip to its original position. 8. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3794 Shift Cable: Service and Repair Shift Control Cable Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the console. 3. Lift up on the cable retainers. 4. Disconnect the cable ends from the shifter. 5. Depress the locking tabs and remove the forward cable from the anchor. 6. Remove the Air Inlet Duct. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3795 7. On the transmission end, disconnect the cable from the shift actuator. 8. Remove both cables from the underhood cable bracket. 9. Position aside the passenger front carpet. 10. Remove the right rear floor duct elbow. 11. Separate the grommet from the floor plan. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3796 12. Pull the cables through the passenger floor opening. Installation Procedure 1. Feed the cable assembly through the passenger floor pan opening. 2. Install the grommet flush with the floor opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3797 3. Install the right rear floor right side elbow duct. 4. Position and install the passenger side carpet. 5. Install the cables into the underhood bracket. 6. Connect the shift cable to the shift actuator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Cable, M/T > Component Information > Adjustments > Page 3798 7. Connect the cables to the shifter 8. Press down on the locking tabs. 9. Install the console. 10. Install the Air Cleaner Inlet Duct. 11. Connect the battery. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End Transmission Mount: Customer Interest M/T - Clunk/Creak Noise From Front End Bulletin No.: 03-07-29-005B Date: July 23, 2004 TECHNICAL Subject: Clunk/Creak Noise from Front End During Low Speed Turns or Maneuvers (Transfer Replacement Rear Transmission Mount Bushing to Side Transmission Mount) Models: 2000-2005 Chevrolet Cavalier 2000-2005 Pontiac Sunfire with 5-Speed Manual Transmission (RPO MM5) Supercede: This bulletin is being revised to add model years and revise the title line. Please discard Corporate Bulletin Number 03-07-29-005A (Section 07-Transmission/Transaxle) Condition Some customers may comment on a clunk noise from the front of the vehicle. This condition is most common during a hard left or right turn when starting from a complete stop. Cause The side (front driver's location) transmission mount is a "floating" or adjustable type of mount which may, under certain conditions, bind within the mount, causing a clunk. Correction To correct the creak or clunk, remove the side transmission mount and transfer a replacement rear transmission mount bushing to the existing side transmission mount. Use the procedure below. 1. Open the vehicle hood and remove the washer fluid reservoir cap. 2. Suitably support and raise the vehicle. 3. Remove the driver's side front wheel and tire assembly. 4. Remove the inner wheel well shroud bolts and retainers. Remove the inner shroud. 5. Remove the outer wheel well shroud bolts and retainers. Remove the outer shroud. 6. Remove the left fender support bolt. 7. Remove the washer fluid reservoir retainers, the electrical connector and the hose. Remove the reservoir. Note: Use a block of wood in conjunction with the transmission jack to prevent possible powertrain damage. 8. Support the transmission using a transmission jack and a block of wood to prevent possible pan damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3807 9. Remove the side transmission mount bolts and transmission mount through bolt. Refer to the illustrations above. Remove the mount from the vehicle. Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment. 10. Referring to the illustration above, observe the up arrow on the illustration along with the rubber molding dimples at the 12 and 6 o'clock positions. Mark the metal portion of the mount using one or all of these indicators. You will use the marks as a guide when installing the new transmission mount bushing. 11. Locate the 4 metal tabs (1) in the illustration. You must bend all 4 tabs 90 degrees to facilitate the removal of the bushing. 12. With the 4 tabs bent in, tap the opposite side of the bushing to slide it out of the mount. You may clamp the mount in a vise if required to accomplish this task. Retention force on the bushing is low so this can be accomplished with little force. 13. Repeat the same procedure with the replacement rear transmission mount. You will remove the bushing in the same manner but you will not need to mark the metal mount body as it will be discarded. Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment. 14. Transfer the rubber bushing from the new rear transmission mount and install it to the original side transmission mount. Use your alignment marks to orient the new bushing in exactly the same way as the original. You must be certain that the bushing is installed in the same direction as the original or you may increase the amount of engine vibration passed to the passenger compartment. 15. Bend the 4 metal retaining tabs down 90 degrees until flat to the metal mount. 16. Install the side transmission mount and secure the bolts. 17. Tighten the side transmission mounting bolts. Tighten Tighten the mounting bolts to 75 N.m (60 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3808 18. Tighten the transmission mount thru bolt. Tighten Tighten the thru bolt to 60 N.m (44 lb ft). 19. Remove the transmission jack and wood block. 20. Install the washer fluid reservoir retainers, electrical connector and hose. 21. Install the fender brace support bolt. 22. Install the outer wheel well shroud and retainers. 23. Install the inner wheel well shroud and retainers. 24. Install the driver's side front tire and wheel assembly. 25. Lower the vehicle 26. Install the washer fluid reservoir cap. 27. Close the hood. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3809 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End Transmission Mount: All Technical Service Bulletins M/T - Clunk/Creak Noise From Front End Bulletin No.: 03-07-29-005B Date: July 23, 2004 TECHNICAL Subject: Clunk/Creak Noise from Front End During Low Speed Turns or Maneuvers (Transfer Replacement Rear Transmission Mount Bushing to Side Transmission Mount) Models: 2000-2005 Chevrolet Cavalier 2000-2005 Pontiac Sunfire with 5-Speed Manual Transmission (RPO MM5) Supercede: This bulletin is being revised to add model years and revise the title line. Please discard Corporate Bulletin Number 03-07-29-005A (Section 07-Transmission/Transaxle) Condition Some customers may comment on a clunk noise from the front of the vehicle. This condition is most common during a hard left or right turn when starting from a complete stop. Cause The side (front driver's location) transmission mount is a "floating" or adjustable type of mount which may, under certain conditions, bind within the mount, causing a clunk. Correction To correct the creak or clunk, remove the side transmission mount and transfer a replacement rear transmission mount bushing to the existing side transmission mount. Use the procedure below. 1. Open the vehicle hood and remove the washer fluid reservoir cap. 2. Suitably support and raise the vehicle. 3. Remove the driver's side front wheel and tire assembly. 4. Remove the inner wheel well shroud bolts and retainers. Remove the inner shroud. 5. Remove the outer wheel well shroud bolts and retainers. Remove the outer shroud. 6. Remove the left fender support bolt. 7. Remove the washer fluid reservoir retainers, the electrical connector and the hose. Remove the reservoir. Note: Use a block of wood in conjunction with the transmission jack to prevent possible powertrain damage. 8. Support the transmission using a transmission jack and a block of wood to prevent possible pan damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3815 9. Remove the side transmission mount bolts and transmission mount through bolt. Refer to the illustrations above. Remove the mount from the vehicle. Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment. 10. Referring to the illustration above, observe the up arrow on the illustration along with the rubber molding dimples at the 12 and 6 o'clock positions. Mark the metal portion of the mount using one or all of these indicators. You will use the marks as a guide when installing the new transmission mount bushing. 11. Locate the 4 metal tabs (1) in the illustration. You must bend all 4 tabs 90 degrees to facilitate the removal of the bushing. 12. With the 4 tabs bent in, tap the opposite side of the bushing to slide it out of the mount. You may clamp the mount in a vise if required to accomplish this task. Retention force on the bushing is low so this can be accomplished with little force. 13. Repeat the same procedure with the replacement rear transmission mount. You will remove the bushing in the same manner but you will not need to mark the metal mount body as it will be discarded. Important: The transmission mount is directional. It is designed to absorb powertrain vibrations in one direction only. Incorrect orientation of the replacement bushing may noticeably increase engine/powertrain vibration in the passenger compartment. 14. Transfer the rubber bushing from the new rear transmission mount and install it to the original side transmission mount. Use your alignment marks to orient the new bushing in exactly the same way as the original. You must be certain that the bushing is installed in the same direction as the original or you may increase the amount of engine vibration passed to the passenger compartment. 15. Bend the 4 metal retaining tabs down 90 degrees until flat to the metal mount. 16. Install the side transmission mount and secure the bolts. 17. Tighten the side transmission mounting bolts. Tighten Tighten the mounting bolts to 75 N.m (60 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3816 18. Tighten the transmission mount thru bolt. Tighten Tighten the thru bolt to 60 N.m (44 lb ft). 19. Remove the transmission jack and wood block. 20. Install the washer fluid reservoir retainers, electrical connector and hose. 21. Install the fender brace support bolt. 22. Install the outer wheel well shroud and retainers. 23. Install the inner wheel well shroud and retainers. 24. Install the driver's side front tire and wheel assembly. 25. Lower the vehicle 26. Install the washer fluid reservoir cap. 27. Close the hood. Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 3817 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement - Rear Transmission Mount: Service and Repair Transmission Mount Replacement - Rear Transmission Mount Replacement - Rear Removal Procedure Important: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Use a jack or a utility stand to raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the mount. 2. Inspect the transmission/transaxle mount. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: ^ The rubber surface is covered with cracks. ^ The rubber is separated from the metal plate of the mount. ^ The rubber is split through the center. 3. If there is movement between the metal plate of the transmission/transaxle mount and the transmission, tighten the transmission mount fasteners to the correct tightening specification. 1. Loosen but do not remove the rear transaxle mount bolts. 2. Raise and support the vehicle. 3. Use the following items in order to support the transaxle: ^ A wood block ^ A jack stand Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement - Rear > Page 3820 4. Remove the rear transaxle mount through-bolt. 5. Remove the rear transaxle mount bolts. 6. Remove the rear transaxle mount. Installation Procedure 1. Position the rear transaxle. 2. Start the rear transaxle mount bolts. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the transaxle mount through-bolt. Tighten the bolt to 75 Nm (55 ft. lbs.). 4. Remove the following items from under the transaxle: ^ The wood block Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement - Rear > Page 3821 ^ The jack stand 5. Lower the vehicle. 6. Install the rear bolts. Tighten the bolts to 75 Nm (55 ft. lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement - Rear > Page 3822 Transmission Mount: Service and Repair Transmission Mount Replacement - Side Transmission Mount Replacement - Side Removal Procedure Important: In order to avoid oil damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Use a jack or a utility stand to raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the mount. 2. Inspect the transmission/transaxle mount Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: ^ The rubber surface is covered with cracks. ^ The rubber is separated from the metal plate of the mount. ^ The rubber is split through the center. 3. If there is movement between the metal plate of the transmission/transaxle mount and the transmission, tighten the transmission mount fasteners to the correct tightening specification. 1. Remove the washer solvent container. 2. Raise and suitably support the vehicle. 3. Remove the left front wheel and tire assemblies. 4. Remove the left front fender liners. 5. Position the following items in order to support the transaxle: ^ A block of wood ^ A jack stand 6. Remove the transaxle mount through-bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Transmission Mount Replacement - Rear > Page 3823 7. Remove the transaxle to engine block bolts. 8. Remove the front transaxle mount. Installation Procedure 1. Install the front transaxle mount. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front transaxle mount bolts. Tighten the bolts to 75 Nm (60 ft. lbs.). 3. Install the front transaxle mount through-bolt. Tighten the bolt to 60 Nm (44 ft. lbs.). 4. Install the left front fender liner. 5. Install the left front tire and the wheel assembly. 6. Remove the jack stand. 7. Lower the vehicle. 8. Install the washer solvent container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3827 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3828 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3829 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3838 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3839 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3843 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3844 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3848 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3849 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3857 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3858 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3859 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3866 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 3867 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Under Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3871 Automatic Transmission Shift Lock Control Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 3875 Shift Solenoid: Diagrams 1-2 Shift Solenoid (SS) Valve Connector, Wiring Harness Side 2-3 Shift Solenoid (SS) Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 3878 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in earn of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3882 Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 3883 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). 2. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams Shift Indicator Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams > Page 3892 Shift Indicator: Description and Operation SHIFT INDICATOR The IPC illuminates the shift indicator when the PCM determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams Brake Switch - TCC: Diagrams Two Way Brake Switch Connector, Wiring Harness Side Four Way Brake Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3901 Automatic Transmission Fluid Pressure Switch Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3902 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transmission side cover. 2. Remove the six bolts from the TFP switch assembly. 3. Remove the TFP switch assembly from the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Installation Procedure 1. Install the TFP switch assembly to the control valve body assembly. The seven pressure switch O-rings are reusable and should remain with the TFP switch assembly. Notice: Refer to Fastener Notice in Service Precautions 2. Install the six bolts to the TFP switch assembly Tighten the bolts to 12 Nm (9 ft. lbs.). 3. Install the transmission side cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Park/Neutral Position (PNP) Switch C1 Park/Neutral Position Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3906 Transmission Position Switch/Sensor: Service and Repair PNP Switch Replacement Removal Procedure 1. Remove the shift linkage. 2. Disconnect the electrical connector. 3. Remove the park/neutral position switch mounting bolts. 4. Remove the park/neutral position switch assembly. Installation Procedure Using Old Switch 1. Place the shift shaft in N (Neutral). 2. Align the flats of the shift shaft with the switch. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 3907 3. Install the park/neutral position switch mounting bolts. Tighten the bolts to 24 Nm (18 ft. lbs.). 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. 4. Turn the ignition switch to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3911 Transmission Speed Sensor: Diagrams Input Speed Sensor Connector, Wiring Harness Side Automatic Transmission Output Shaft Speed Sensor Connector, Wiring Harness Side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3912 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the electrical connector at the vehicle speed sensor. 4. Remove the retaining stud and the sensor. Pull straight out in order to avoid damage to tire case. Installation Procedure 1. Clean and dry the vehicle speed sensor. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the vehicle speed sensor and the retaining stud. Tighten the stud to 12 Nm (97 inch lbs.). 3. Install the electrical connector at the sensor. 4. Lower the vehicle. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Electronic Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations Vehicle Speed Sensor {VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3920 Vehicle Speed Sensor (VSS) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3921 Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Replacement Removal Procedure 1. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. 2. Remove the retainer bolt. 3. Remove the retainer. 4. Remove the VSS. 5. Remove the O-ring. Installation Procedure 1. Lubricate a new O-ring with DEXRON III transmission fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Locations > Page 3922 2. Install the new O-ring. 3. Install the VSS retainer. Install the Vehicle Speed Sensor (VSS) assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the VSS retainer bolt. Tighten the bolt to 9 Nm (80 inch lbs.). 5. Connect the VSS connector to the VSS. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position 2. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material. 3. Disengage the electrical Connector Position Assurance (CPA) locking tab (1) from the connector sliding cover lock tab. 4. Depress the cover lock tab, then move the sliding connector cover (2) to the open position. 5. Disconnect the electrical harness connector (4) from the EBCM (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Page 3928 6. Remove the 4 EBCM-to-BPMV retaining bolts. Important: ^ Do not pry apart the EBCM (1) from the BPMV (2) using a tool. Be careful not to damage seal on the EBCM or the mating surface of the BPMV. ^ Care must be taken not to damage the solenoids when the EBCM is removed from the BPMV. 7. Separate the EBCM (1) from the BPMV (2) by carefully pulling apart. Installation Procedure 1. Clean the sealing surface of the BPMV, with denatured alcohol and a clean shop cloth. 2. If the EBCM that was removed is being reinstalled, clean the seal and sealing surface of the EBCM, with denatured alcohol and a clean shop cloth. 3. Install the EBCM (1) to the BPMV (2). Use care when aligning the EBCM to the BPMV electrical terminals. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 EBCM-to-BPMV retaining bolts. Tighten the bolts in a cries-cross pattern. ^ Tighten the bolts to 5 Nm (44 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Page 3929 5. Connect the electrical harness connector (4) to the EBCM (3). 6. Depress the cover lock tab, then move the sliding connector cover (2) to the home position to lock. 7. Engage the electrical connector CPA locking tab (1) to the connector sliding cover lock tab. Important: Do NOT start the engine, but only turn the ignition switch to the ON position. 8. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Brake Pressure Modulator Valve (BPMV) Bracket Replacement Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the EBCM/BPMV assembly to mounting bracket bolt. 3. Without disconnecting any brake pipes, remove the EBCM/BPMV assembly from mounting bracket, then carefully reposition and support the modulator assembly to provide access for bracket removal. 4. Remove the master cylinder mounting nuts. 5. Remove the BPMV bracket from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 3934 1. Install the BPMV bracket into position in the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the master cylinder mounting nuts. ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 3. Install the EBCM/BPMV assembly to the mounting bracket. 4. Install the EBCM/BPMV assembly to mounting bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 3935 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Brake Pressure Modulator Valve (BPMV) Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Clean the Brake Pressure Modulator Valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material. 3. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material. 4. Disengage the electrical Connector Position Assurance (CPA) locking tab (1) from the connector sliding cover lock tab. 5. Depress the cover lock tab, then move the sliding connector cover (2) to the open position. 6. Disconnect the electrical connector from the EBCM. Important: Prior to disconnecting the brake pipes from the ABS modulator assembly, note the locations of the brake pipes to the valve assembly, to aid during installation. 7. Disconnect the caliper and wheel cylinder brake pipes (2) from the BPMV. 8. Cap the brake pipe ends to prevent brake fluid loss and contamination. 9. Plug the brake pipe ports on the BPMV to prevent fluid loss and contamination. 10. Carefully reposition the caliper and wheel cylinder brake pipes (2) to gain access to the master cylinder pipes (1). 11. Disconnect the master cylinder brake pipes (1) from the BPMV. 12. Cap the brake pipe ends to prevent brake fluid loss and contamination. 13. Plug the brake pipe ports on the BPMV to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 3936 14. Remove the EBCM/BPMV assembly to mounting bracket bolt. 15. Remove the EBCM/BPMV assembly from the vehicle. 16. Remove the 4 EBCM-to-BPMV retaining bolts. Important: ^ Do not pry apart the EBCM (1) from the BPMV (2) using a tool. Be careful not to damage seal on the EBCM or the mating surface of the BPMV. ^ Care must be taken not to damage the solenoids when the EBCM is removed from the BPMV. 17. Separate the EBCM (1) from the BPMV (2) by carefully pulling apart. Installation Procedure Important: When installing a new brake modulator assembly, do NOT remove the shipping plugs from the pipe ports until after installation into the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 3937 1. Clean the seal and sealing surface of the EBCM, with denatured alcohol and a clean shop cloth. 2. If the BPMV that was removed is being reinstalled, clean the sealing surface of the BPMV, with denatured alcohol and a clean shop cloth. 3. Install the EBCM (1) to the BPMV (2). Use care when aligning the EBCM to the BPMV electrical terminals. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 EBCM-to-BPMV retaining bolts. Tighten the bolts in a cries-cross pattern. ^ Tighten the bolts to 5 Nm (44 inch lbs.). 5. Install the EBCM/BPMV assembly to the mounting bracket. 6. Install the EBCM/BPMV assembly to mounting bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 7. Remove the caps from the master cylinder brake pipe ends Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 3938 8. Remove the plugs from the master cylinder ports on the BPMV. 9. Connect the master cylinder brake pipes (1) to the BPMV, in the same location as removed. 10. Tighten the brake pipe fittings at the BPMV. ^ Tighten the fittings to 24 Nm (18 ft. lbs.). 11. Remove the caps from the caliper and wheel cylinder brake pipe ends. 12. Remove the plugs from the caliper and wheel cylinder ports on the BPMV. 13. Connect the caliper and wheel cylinder brake pipes (2) to the BPMV, in the same location as removed. 14. Tighten the brake pipe fittings at the BPMV. ^ Tighten the fittings to 24 Nm (18 ft. lbs.). 15. Connect the electrical harness connector (4) to the EBCM (3). 16. Depress the cover lock tab, then move the sliding connector cover (2) to the home position to lock. 17. Engage the electrical connector CPA locking tab (1) to the connector sliding cover lock tab. 13. Perform the ABS Automated Bleed Procedure. Important: Do NOT start the engine, but only turn the ignition switch to the ON position. 19. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Carefully remove the instrument panel dimmer switch bezel from the dash. 2. Disconnect the electrical connector from the traction control switch. 3. Remove the traction control switch from the instrument panel dimmer switch bezel. To avoid damage to the instrument panel dimmer switch bezel, use a flat bladed tool on the back side of the traction control switch to release the retaining clips. Installation Procedure 1. Install the traction control switch to the instrument panel dimmer switch bezel. 2. Connect the electrical connector to the traction control switch. 3. Align the instrument panel dimmer switch bezel to the dash and carefully press the retaining clips into the correct mounting areas on the dash. 4. Verify the repair. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: Customer Interest ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 3950 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 3956 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 3957 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the front wheel speed sensor. 3. Remove the wheel speed sensor retaining bolt. 4. Remove the wheel speed sensor from the steering knuckle. If the sensor will not slide out of the knuckle perform the following steps: 4.1. Remove the brake rotor to access the other side of the knuckle. 4.2. Using a blunt punch, or equivalent tool, push the sensor from the outboard side of the knuckle. 5. Inspect the removed wheel speed sensor and the steering knuckle to ensure that the sensor's locating pin has not broken off in the locating hole of the knuckle. If the locating pin remains in the locating hole of the knuckle, perform the following steps. 5.1. Remove the brake rotor, if it has not already been removed, to access the other side of the knuckle. 5.2. Using a blunt punch, or equivalent tool, remove the broken locating pin from the outboard side of the knuckle. 5.3. If necessary, clean the locating hole in the knuckle using sand paper wrapped around a screwdriver, or other suitable tool. Never attempt to enlarge the hole. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 3958 1. Install the front wheel speed sensor to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front wheel speed sensor retaining bolt. ^ Tighten the bolt to 12 Nm (107 inch lbs.). 3. Connect the electrical connector to the front wheel speed sensor. 4. Lower the vehicle. 5. Perform the Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure ^ Items Required ^ A scan tool ^ J 29532 pressure bleeder with the proper master cylinder adapter ^ Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container ^ A hoist ^ An unbreakable plastic bleeder bottle equipped with a hose to recover fluid at the wheels ^ An assistant, if needed ^ The suitable safety attire, including safety glasses Automated Bleed Procedure Perform the automated ABS bleed procedure whenever one of the following conditions occurs: ^ Manual bleeding at the wheel cylinders does not achieve the desired pedal height or feel. ^ You replace the Brake Pressure Modulator Valve (BPMV). ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions applies, use standard bleed procedures. This procedure uses a scan tool in order to cycle the system solenoid valves and to run the pump motor in order to purge the air from the secondary circuits. These secondary circuits are normally closed, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or the calipers where the air can be purged out of the system. Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. 2. Connect a scan tool to the DLC connector and select Current and History DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks, repair as needed. Preliminary Setup 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Connect the J 29532 according to the manufacturer's instructions. 4. Turn the ignition switch to the ON position, engine OFF. 5. Connect a scan tool and establish communication with the ABS system. 6. Pressurize the bleeding tool to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the J 29532 at 35 psi, and all the bleeder screws in the closed position, select the Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and the front release valves for 1 minute. After the cycling has stopped the scan tool will enter a cool down mode and display a 3 minute timer. The auto bleed will not continue until this timer expires. You cannot override this timer. 3. The scan tool will request the technician to open one of the bleeder valves. The scan tool will then cycle this valve and the pump motor for 1 minute. 4. The scan tool repeats step 3 for the remaining bleeder valves. 5. With the J 29532 still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake pipes. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the J 29532 and then disconnect the J 29532 from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. 9. Repeat steps 1-8 until the pedal is acceptable. 10. Remove the scan tool from the DLC. 11. Lower the vehicle. 12. Inspect the brake fluid level in the master cylinder. 13. Road test the vehicle while verifying that the brake pedal remains high and firm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3964 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 392667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3965 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3966 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 44894-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3967 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve. then disconnect the J 29532, or equivalent, from the J 44894-A. 23. Remove the J 44894-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 3968 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 115, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Disconnect the accelerator cable from the accelerator pedal. 2. Remove the retaining clip (1) and outer washer (2) from the brake pedal. 3. Disconnect the brake booster pushrod (3) from the brake pedal. 4. Remove the inner washer (4) from the brake pedal. 5. Remove the stop lamp switch from the brake pedal assembly. 6. Remove the cruise control release switch, if equipped, from the brake pedal assembly. 7. Release the electrical harness from the brake pedal assembly. 8. Remove the brake booster mounting nuts (2). 9. Remove the brake pedal assembly upper mounting nut. 10. Remove the brake pedal assembly (1) from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 3972 1. Install the brake pedal assembly (1) to the vehicle. 2. Loosely install the brake pedal assembly upper mounting nut. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the vacuum brake booster mounting nuts (2). ^ Tighten the nuts to 27 Nm (20 inch lbs.). 4. Tighten the brake pedal assembly upper mounting nut. ^ Tighten the nut to 27 Nm (20 inch lbs.). 5. Secure the electrical harness to the brake-pedal assembly. 6. Install the stop lamp switch to the brake pedal assembly. 7. Install the cruise control release switch, if equipped, to the brake pedal assembly. 8. Install the inner washer (4) to the brake pedal. 9. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal. 10. Connect the brake pedal pushrod (3) to the brake pedal. 11. Install the outer washer (2) and retaining clip (1) to the brake pedal. 12. Adjust the stop lamp switch. 13. Adjust the cruise control release switch, if equipped. 14. Connect the accelerator cable to the accelerator pedal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams Brake Warning System Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul Brake Caliper: Service and Repair Brake Caliper Overhaul Brake Caliper Overhaul ^ Tools Required J 29077-A Caliper Piston Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 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. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the piston dust boot seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 3981 6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the caliper piston into the caliper bore. 4. Install the new piston dust boot seal over the piston. 5. Using the J 29077-A, fully seat the dust boot seal into the counterbore. 6. Install the bleeder valve and cap to the caliper and tighten the valve securely. 7. Install the front brake caliper to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 3982 Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 12. Remove the brake hose (3) from the brake caliper. 13. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 14. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination. 15. Fully loosen the caliper bolts from the steering knuckle. 16. Remove the brake caliper from the steering knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 3983 17. Remove the brake pads from the caliper. 18. Remove the disc brake caliper bolts (1) from the caliper assembly (3). 19. Inspect the caliper bolts (1) for rust, corrosion and/or damage. 20. If the bolts are rusty, corroded, and/or damaged, replace the bolts (1) and replace the bushings (2). Installation Procedure 1. Lubricate the caliper bushings and install the caliper bolts to the caliper. Important: The outer brake pad must be mounted with the leading edge of the wear sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 2. Install the brake pads to the caliper. 3. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion. 4. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 3984 5. Install the caliper assembly to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the caliper bolts to the steering knuckle. ^ Tighten the bolts to 51 Nm (38 ft. lbs.). 7. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Important: Install NEW copper brake hose gaskets (2). 8. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). Notice: Refer to Fastener Notice in Service Precautions. 9. Install the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Remove the wheel nuts securing the rotor to the hub. 12. Install the tire and wheel assembly. 13. Lower the vehicle. 14. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 15. Slowly release the brake pedal. 16. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 3985 Brake Caliper: Service and Repair Disc Brake Hardware Replacement Disc Brake Hardware Replacement Removal Procedure 1. Remove the disc brake pads. 2. Remove the disc brake caliper bolts (1) from the caliper assembly. 3. Remove the caliper bushings (2) from the brake caliper assembly, and discard the bushings. 4. Inspect the caliper bushing bores in the caliper assembly. Remove any debris or corrosion from the bores. 5. Inspect the bolts for rust, corrosion, and/or damage. If any of these conditions are present, replace the bolts. Installation Procedure 1. Apply a thin layer of high temperature silicone brake lubricant to the exterior of the NEW brake caliper bushings (2). 2. Install the NEW bushings (2) into the caliper assembly. Ensure that the chamfered end of the bushings are positioned outboard when in-vehicle. 3. Apply a liberal amount of high temperature silicone brake lubricant to the interior of the NEW bushings (2). Ensure that the lubricant fills the cavities beside the ribs on the inside of the bushings (4). 4. Apply a thin layer of high temperature silicone brake lubricant to the bushing surface of the caliper bolts. 5. Install the caliper bolts to the bushings. 6. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion. 7. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle. 8. Install the disc brake pads. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Brake Pads Replacement Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outboard brake pad. 8. Tighten the C-clamp evenly until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Fully loosen the caliper bolts (1, 4) from the steering knuckle (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 3991 Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 11. Without disconnecting the hydraulic brake flexible hose, remove the caliper assembly (2) from the steering knuckle. Support the caliper with heavy mechanic's wire (1), or equivalent. 12. Remove the brake pads from the caliper. 13. Remove the disc brake caliper bolts (1) from the caliper assembly (3). 14. Inspect the caliper bolts (1) for rust, corrosion and/or damage. 15. If the bolts are rusty, corroded, and/or damaged, replace the bolts (1) and replace the bushings (2). Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 3992 1. Install a large C-clamp (2) over the body of the brake caliper (1), with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad or a wood block installed against the caliper piston. 2. Tighten the C-clamp (2) evenly until the caliper piston is compressed completely into the caliper bore. 3. Remove the C-clamp and the old brake pad or wood block from the caliper. 4. Lubricate the caliper bushings and install the caliper bolts to the caliper. Important: The outer brake pad must be mounted with the leading edge of the wear sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 5. Install the brake pads to the caliper. 6. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion. 7. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle. 8. Install the caliper assembly (2) to the steering knuckle (3). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 3993 9. Tighten the caliper bolts (14) to the steering knuckle (3). ^ Tighten the bolts to 51 Nm (38 ft. lbs.). 10. Remove the wheel nuts securing the rotor to the hub. 11. Install the tire and wheel assembly. 12. Lower the vehicle. 13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 14. Slowly release the brake pedal. 15. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. 16. Fill the brake master cylinder reservoir to the proper level. 17. Burnish the pads and rotors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 3994 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws, Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 3999 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4000 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4001 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4002 WARRANTY INFORMATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4003 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4004 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4005 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4006 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4007 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4008 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4009 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4010 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4011 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4012 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4013 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4014 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4015 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4016 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4017 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 4018 Brake Align Order Form Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4019 Brake Rotor/Disc: Specifications Brake Rotor Discard Thickness ........................................................................................................................................................ 18.70 mm (0.736 inch) Brake Rotor Maximum Allowable Thickness Variation ................................................................................................................... 0.025 mm (0.001 inch) Brake Rotor Minimum Allowable Thickness after Refinish ........................................................................................................... 18.776 mm (0.739 inch) Brake Rotor Thickness - New ............................................................................................................................................................ 19.96 mm (0.786 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Brake Rotor Replacement ^ Tools Required J 141013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Using the C-clamp, compress the piston into the caliper bore just enough to allow the caliper to slide away from the rotor. 5. Remove the C-clamp. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Important: Do NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Remove the brake caliper with brake pads as an assembly (2) from the steering knuckle and support the assembly with heavy mechanic's wire (1), or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. 7. Matchmark the position of the brake rotor (3) to the wheel studs. 8. Remove the brake rotor (3). Installation Procedure Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled Lateral Runout (LRO) of the brake rotor, which could lead to brake pulsation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 4022 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor (3) to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. 7. Install the caliper assembly (2) to the steering knuckle. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 4023 Brake Rotor/Disc: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Road test a vehicle under safe conditions and while obeying all traffic laws, Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Caution: Refer to Brake Dust Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 4024 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing Brake Rotor Refinishing ^ Tools Required J 41013 Rotor Resurfacing Kit - J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution in Service Precautions. Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: ^ Brake system noise - squeal, growl, groan ^ Uneven and/or premature disc brake pad wear ^ Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface ^ Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: ^ Thickness variation in excess of the maximum allowable specification ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive bluing discoloration ^ Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled Lateral Runout (LRO) that exceeds the maximum allowable specification. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled Lateral Runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 12.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 12.2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 12.3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled Lateral Runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Drum Brake Backing Plate Replacement Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Remove the brake shoes. 5. Remove the universal spring (1) from the brake backing plate. 6. Release the rear park brake cable end fitting (1) from the drum brake backing plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 4029 7. Remove the wheel cylinder (3). 8. Remove the wheel bearing/hub assembly. 9. Remove the brake backing plate. Installation Procedure 1. Install the brake backing plate. 2. Install the wheel bearing/hub assembly. 3. Install the wheel cylinder (3). 4. Secure the rear park brake cable end fitting to the brake backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair > Page 4030 5. Install the universal spring (1) to the backing plate. 6. Install the brake shoes. 7. Adjust the drum brakes. 8. Install the brake drum. 9. Bleed the hydraulic brake system. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Drum Brake Component Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 4034 Brake Drum: Adjustments Drum Brake Adjustment ^ Tools Required J 21177-A Drum-to-Brake Shoe Clearance Gage Caution: Refer to Brake Dust Caution in Service Precautions. 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the rear tire and wheel assemblies. 4. Remove the brake drums. 5. Position the J 21177-A to widest point of the brake drum inside diameter. 6. Firmly hand tighten the set screw on the J 21177-A. 7. Remove the J 21177-A from the brake drum and position it over the corresponding brake shoe assembly at its widest point. 8. While holding the J 21177-A in position, insert a 0.635 mm (0.025 inch) feeler gage between one side of the J 21177-A, and the corresponding brake shoe. 9. Rotate the brake shoe adjuster screw until the brake shoes contact the J 21177-A, and the feeler gage. ^ Brake shoe-to-drum clearance: 0.635 mm (0.025 inch). 10. Repeat the above steps for the opposite brake drum and brake shoe assembly. 11. Install the brake drums. 12. Restore the tension to the park brake cable system. 13. Adjust the park brake. 14. Install the rear tire and wheel assemblies. 15. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement Brake Drum: Service and Repair Brake Drum Replacement Brake Drum Replacement ^ Tools Required J 41013 Rotor/Drum Flange Resurfacing Kit - J 42450-A Wheel Hub/Flange Resurface Kit Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Check to ensure that the park brake is fully released. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the brake drum. 5. If the brake drum is to be reinstalled to the vehicle, use the J 41013 to clean any rust or corrosion from the hub/flange mating surface of the brake drum. 6. If necessary, carefully remove any corrosion from the edge of the drum braking surface in order to ease installation. 7. Use the J 42450-A to clean the wheel hub flange. Installation Procedure 1. Adjust the drum brakes. 2. Install the brake drum. 3. Install the tire and wheel assembly. 4. Apply the brakes approximately three times in order to seat and center the brake shoes within the drum. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4037 Brake Drum: Service and Repair Brake Drum Refinishing Brake Drum Refinishing ^ Tools Required J 41013 Rotor/Drum Flange Resurfacing Kit - J 42450-A Hub Cleaning Kit Caution: Refer to Brake Dust Caution in Service Precautions. 1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions: ^ Brake system noise (squeal, growl, groan) ^ Uneven and/or premature brake lining wear ^ Superficial or cosmetic corrosion/rust of the brake drum surface ^ Scoring of the brake drum surface (less than the maximum allowable specification) 2. Brake drums should only be refinished if the following conditions exist: ^ Excessive corrosion/rust and/or pitting ^ Cracks and/or heat spots ^ Excessive bluing discoloration ^ Scoring of the brake drum surface (in excess of the maximum allowable specification) ^ Radial runout in excess of the maximum allowable specification 3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification: 3.1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. 3.2. Inspect each of the brake drums for excessive surface wear and/or radial runout. 4. If the brake drums can be refinished, proceed with the rotor refinishing procedure. 5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange. 6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions. 7. Ensure that any vibration dampening attachments are securely in place. 8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface. 9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe. 10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe. 11. Following the brake lathe manufacturer's instructions, refinish the brake drum. 12. After each successive cut, inspect the brake drum diameter. 13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced. 14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish: 14.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 14.2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper. ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper. 14.3. After applying a non-directional finish, clean each friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner 15. Remove the brake drum from the brake lathe. Important: Failure to clean the corrosion from the wheel bearing flange may result in increased lateral runout of the brake drum and brake system pulsation. 16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4038 Brake Drum: Service and Repair Drum Brake Hardware Replacement Drum Brake Hardware Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. 5. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4039 6. Remove the universal spring (1) from the brake backing plate. Installation Procedure 1. Install the universal spring (1) to the brake backing plate. 2. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out, away from the hub, while installing the spring end into the shoe web hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4040 3. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out, away from the hub, while installing the spring end into the shoe web hole. 4. Install the brake drum. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4041 Brake Drum: Service and Repair Drum Brake Adjusting Hardware Replacement Drum Brake Adjusting Hardware Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. 4. Remove the adjuster spring. Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole. 5. Remove the adjuster actuator lever from the pivot. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4042 6. Using the J 38400 (1), spread the top of the brake shoes apart and remove the adjuster assembly (2). 7. Inspect the adjuster assembly for the following conditions: ^ Binding or seized threaded adjuster assembly. ^ Damaged or missing adjuster screw teeth. 8. Replace the adjuster assembly if any of the conditions listed are present. Installation Procedure 1. Using the J 38400 (1), spread the top of the brake shoes apart and install the adjuster assembly (2) to the brake shoes. 2. Install the adjuster actuator lever to the pivot and the adjuster assembly. Ensure that the lever is properly engaged between the adjuster assembly and the brake shoe. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Replacement > Page 4043 Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. 3. Install the adjuster spring. Ensure that the loop end of the spring fully engages the tab on the actuator lever. 4. Adjust the drum brakes. 5. Install the brake drum. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Brake Shoe-to-Drum Clearance ......................................................................................................................................................... 0.635 mm (0.025 inch) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4047 Brake Shoe: Service and Repair Brake Shoe Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. 4. Remove the adjuster spring. Disengage the adjuster spring hook end from the tab on the adjuster actuator lever, then release the spring from the brake shoe web hole. 5. Remove the adjuster actuator lever from the pivot Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4048 6. Using the J 38400 (1), spread the top of the brake shoes apart and remove the adjuster assembly (2) from the brake shoes. 7. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring with the tool while removing the secondary brake shoe. 8. Release the park brake cable from the park brake lever on the secondary shoe. 9. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out of the shoe web hole. Hold the universal spring with the tool while removing the primary brake shoe. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4049 1. Apply a thin, light coat of high temperature silicone brake lubricant to the brake shoe contact surfaces of the brake backing plate. 2. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out while installing the primary brake shoe. Ensure that the universal spring engages the brake shoe web hole. 3. Install the park brake cable to the park brake lever on the secondary brake shoe. 4. Position the hook end of the J 38400 (1) under the universal spring and lightly pull the universal spring end out while installing the secondary brake shoe. Ensure that the universal spring properly engages the brake shoe web hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 4050 5. Using the J 38400 (1), spread the top of the brake shoes apart and install the adjuster assembly (2) to the brake shoes. 6. Install the adjuster actuator lever to the pivot and the adjuster assembly. Ensure that the lever is properly engaged between the adjuster assembly and the brake shoe. Notice: Do not over stretch the adjuster spring. Damage can occur if the spring is over stretched. 7. Install the adjuster spring. Ensure that the loop end of the spring fully engages the tab on the actuator lever. 8. Adjust the drum brakes. 9. Install the brake drum. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4055 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Clean any debris and contaminants from around the wheel cylinder. 5. Remove the wheel cylinder bleeder cap and valve (2). 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and contamination. 7. Remove the wheel cylinder mounting bolts (3). 8. Using the J 38400, spread the top of the brake shoes apart, then remove the wheel cylinder from the brake backing plate. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4056 1. Using the J 38400, spread the top of the brake shoes apart, then install the wheel cylinder to the brake backing plate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel cylinder mounting bolts (3). ^ Tighten the bolts to 16 Nm (12 ft. lbs.). 3. Remove the cap from the brake pipe end. 4. Connect the brake pipe fitting (1) at the wheel cylinder. ^ Tighten the fitting to 18 Nm (13 ft. lbs.). 5. Install the wheel cylinder bleeder valve. ^ Tighten the valve to 8 Nm (71 inch lbs.). 6. Install the brake drum. 7. Bleed the hydraulic brake system. 8. Install the bleeder valve cap. 9. Adjust the drum brakes. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure ^ Items Required ^ A scan tool ^ J 29532 pressure bleeder with the proper master cylinder adapter ^ Delco Supreme 11 or equivalent Dot 3 brake fluid from a clean, sealed container ^ A hoist ^ An unbreakable plastic bleeder bottle equipped with a hose to recover fluid at the wheels ^ An assistant, if needed ^ The suitable safety attire, including safety glasses Automated Bleed Procedure Perform the automated ABS bleed procedure whenever one of the following conditions occurs: ^ Manual bleeding at the wheel cylinders does not achieve the desired pedal height or feel. ^ You replace the Brake Pressure Modulator Valve (BPMV). ^ Extreme loss of brake fluid has occurred. ^ Air ingestion is suspected. If none of the above conditions applies, use standard bleed procedures. This procedure uses a scan tool in order to cycle the system solenoid valves and to run the pump motor in order to purge the air from the secondary circuits. These secondary circuits are normally closed, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside the BPMV to flow out toward the wheel cylinders or the calipers where the air can be purged out of the system. Preliminary Inspection 1. Inspect the battery for full charge, repair the battery and charging system as necessary. 2. Connect a scan tool to the DLC connector and select Current and History DTCs. Repair any DTCs prior to performing the ABS bleed procedure. 3. Inspect for visual damage and leaks, repair as needed. Preliminary Setup 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Turn the ignition switch to the OFF position. 3. Connect the J 29532 according to the manufacturer's instructions. 4. Turn the ignition switch to the ON position, engine OFF. 5. Connect a scan tool and establish communication with the ABS system. 6. Pressurize the bleeding tool to 35 psi. Performing the Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. With the J 29532 at 35 psi, and all the bleeder screws in the closed position, select the Automated Bleed Procedure on the scan tool and follow the instructions. 2. The first part of the automated bleed procedure will cycle the pump and the front release valves for 1 minute. After the cycling has stopped the scan tool will enter a cool down mode and display a 3 minute timer. The auto bleed will not continue until this timer expires. You cannot override this timer. 3. The scan tool will request the technician to open one of the bleeder valves. The scan tool will then cycle this valve and the pump motor for 1 minute. 4. The scan tool repeats step 3 for the remaining bleeder valves. 5. With the J 29532 still attached to the vehicle and maintaining 35 psi, the scan tool will instruct the technician to independently open each bleeder screw for approximately 20 seconds. This should allow any remaining air to be purged from the brake pipes. 6. When the automated bleed procedure is completed, the scan tool will display the appropriate message. 7. Remove pressure from the J 29532 and then disconnect the J 29532 from the vehicle. 8. Depress the brake pedal in order to gauge the pedal height and feel. 9. Repeat steps 1-8 until the pedal is acceptable. 10. Remove the scan tool from the DLC. 11. Lower the vehicle. 12. Inspect the brake fluid level in the master cylinder. 13. Road test the vehicle while verifying that the brake pedal remains high and firm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4063 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 392667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit- install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4064 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4065 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 44894-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, or if you have disconnected the brake pipes from the proportioning valve assembly or the brake modulator assembly, you must perform the following steps to bleed air at the ports of the hydraulic component: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the brake pipes installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly, loosen and separate one of the brake pipes from the port of the component. For the proportioning valve assembly or the brake modulator assembly, perform these steps in the sequence of system flow; begin with the fluid feed pipes from the master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the component. 3.4. Connect the brake pipe to the component and tighten securely. 3.5. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the component. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the component. 3.9. With the brake pipe installed securely to the master cylinder, proportioning valve assembly, or brake modulator assembly -after all air has been purged from the first port of the component that was bled -loosen and separate the next brake pipe from the component, then repeat steps 3.3-3.8, until each of the ports on the component has been bled. 3.10. After completing the final component port bleeding procedure, ensure that each of the brake pipe-to-component fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11 GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 44894-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 44894-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuitinstall a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4066 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve. then disconnect the J 29532, or equivalent, from the J 44894-A. 23. Remove the J 44894-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly press and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 26.1. Inspect the brake system for external leaks. 26.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 4067 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 115, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul Brake Caliper: Service and Repair Brake Caliper Overhaul Brake Caliper Overhaul ^ Tools Required J 29077-A Caliper Piston Seal Installer Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake caliper from the vehicle. 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. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the piston dust boot seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 4072 6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. Assembly Procedure 1. Lubricate the new piston seal with Delco Supreme II GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the caliper piston into the caliper bore. 4. Install the new piston dust boot seal over the piston. 5. Using the J 29077-A, fully seat the dust boot seal into the counterbore. 6. Install the bleeder valve and cap to the caliper and tighten the valve securely. 7. Install the front brake caliper to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 4073 Brake Caliper: Service and Repair Brake Caliper Replacement Brake Caliper Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Remove the tire and wheel assembly. 6. install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. 10. Clean all dirt and foreign material from the brake hose end. 11. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 12. Remove the brake hose (3) from the brake caliper. 13. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 14. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination. 15. Fully loosen the caliper bolts from the steering knuckle. 16. Remove the brake caliper from the steering knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 4074 17. Remove the brake pads from the caliper. 18. Remove the disc brake caliper bolts (1) from the caliper assembly (3). 19. Inspect the caliper bolts (1) for rust, corrosion and/or damage. 20. If the bolts are rusty, corroded, and/or damaged, replace the bolts (1) and replace the bushings (2). Installation Procedure 1. Lubricate the caliper bushings and install the caliper bolts to the caliper. Important: The outer brake pad must be mounted with the leading edge of the wear sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 2. Install the brake pads to the caliper. 3. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion. 4. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 4075 5. Install the caliper assembly to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the caliper bolts to the steering knuckle. ^ Tighten the bolts to 51 Nm (38 ft. lbs.). 7. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Important: Install NEW copper brake hose gaskets (2). 8. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). Notice: Refer to Fastener Notice in Service Precautions. 9. Install the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). 10. Bleed the hydraulic brake system. 11. Remove the wheel nuts securing the rotor to the hub. 12. Install the tire and wheel assembly. 13. Lower the vehicle. 14. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 15. Slowly release the brake pedal. 16. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Overhaul > Page 4076 Brake Caliper: Service and Repair Disc Brake Hardware Replacement Disc Brake Hardware Replacement Removal Procedure 1. Remove the disc brake pads. 2. Remove the disc brake caliper bolts (1) from the caliper assembly. 3. Remove the caliper bushings (2) from the brake caliper assembly, and discard the bushings. 4. Inspect the caliper bushing bores in the caliper assembly. Remove any debris or corrosion from the bores. 5. Inspect the bolts for rust, corrosion, and/or damage. If any of these conditions are present, replace the bolts. Installation Procedure 1. Apply a thin layer of high temperature silicone brake lubricant to the exterior of the NEW brake caliper bushings (2). 2. Install the NEW bushings (2) into the caliper assembly. Ensure that the chamfered end of the bushings are positioned outboard when in-vehicle. 3. Apply a liberal amount of high temperature silicone brake lubricant to the interior of the NEW bushings (2). Ensure that the lubricant fills the cavities beside the ribs on the inside of the bushings (4). 4. Apply a thin layer of high temperature silicone brake lubricant to the bushing surface of the caliper bolts. 5. Install the caliper bolts to the bushings. 6. Thoroughly clean the brake pad mating surface on the steering knuckle of any surface debris and/or corrosion. 7. Apply a thin layer of high temperature silicone brake lubricant to the brake pad mating surface on the steering knuckle. 8. Install the disc brake pads. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 4081 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement ^ Tools Required J 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. 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. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Important: When servicing brake pipes, note the following: ^ If sectioning brake pipe, use replacement pipe of the same type and outside diameter. ^ Use fittings of the appropriate size and type. ^ Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the section of brake pipe to be replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. ^ Allow adequate clearance in order to maneuver the J 45405. ^ Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. ^ 6.35 mm (0.250 inch) for 4.76 mm (3/16 inch) diameter pipe Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405, carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4086 9. Strip the nylon coating from the brake pipe ends to be flared, if necessary. ^ Select the appropriate blade on the coating stripping tool included in the J 45405, by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. ^ 6.35 mm (0.250 inch) blade for 4.76 mm (3/16 inch) diameter pipe ^ Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. ^ While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the metal surface of the brake pipe. ^ Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. ^ After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. ^ Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. ^ Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. ^ 6.35 mm (0.250 inch) for 4.76 mm (3/16 inch) diameter pipe 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405. 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4087 13. Loosen the die clamping screw of the J 45405. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4088 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Loosen the die clamping screw and remove the dies and pipe. 26. If necessary, lightly tap the dies until the die halves separate. 27. Inspect the brake pipe flare for correct shape and diameter (a). ^ 7.10 mm (0.279 inch) -a/- 0.18 mm (0.007 inch) flare diameter for 4.76 mm (3/16 inch) diameter pipe 28. If necessary, using the removed section of pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Important: When installing the pipe, maintain a clearance of 19 mm (3/4 inch) from all moving or vibrating components. 29. Install the pipe to the vehicle with the appropriate brake pipe unions as required. 30. If previously released, secure the brake pipe to the retainers. 31. Bleed the hydraulic brake system. 32. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4089 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Brake Hose Replacement - Front Caution: Refer to Brake Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose ends and brake pipe fitting. 4. Using a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose (2). Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination. 5. Remove the hose retaining clip (3) from the front brake hose (2). 6. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 7. Remove the brake hose (3) from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 9. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4090 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Important: Install NEW copper brake hose gaskets (2). 2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the brake hose-to-brake caliper bolt to the brake caliper. ^ Tighten the bolt to 50 Nm (37 ft. lbs.). Important: Make sure the brake hose is not twisted. 4. Install the brake hose (2) to the brake hose bracket. 5. Install the hose retaining clip (3) to the front brake hose (2). 6. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 7. Using a backup wrench on the hose fitting, connect the brake pipe fitting at the front brake hose (2). ^ Tighten the fitting to 23 Nm (17 ft. lbs.). 8. Install the tire and wheel assembly. 9. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition. 10. Bleed the hydraulic brake system. 11. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4091 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear Brake Hose Replacement - Rear Caution: Refer to Brake Fluid irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hose ends and brake pipe fittings. 4. Using a backup wrench on the hose fitting, disconnect the brake pipe fittings from the brake hose. Cap or plug the brake pipe fitting ends and the brake hose ends to prevent fluid loss and contamination. 5. Remove the brake hose retaining clips (1) and (2) from the hose mounting brackets. 6. Remove the hose (3) from the hose mounting brackets. Installation Procedure 1. Install the brake hose (3) to the brake hose mounting brackets. Align the hose fitting with the notch in the bracket. Use the hose paint stripe as a visual aid. 2. Install the hose retaining clips (1) and (2) onto the hose fittings at the hose brackets. Notice: Refer to Fastener Notice in Service Precautions. 3. Using a backup wrench on the hose fitting, connect the brake pipe fittings at the rear brake hose. ^ Tighten the fittings to 23 Nm (17 ft. lbs.). 4. Install the tire and wheel assembly. 5. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 4092 6. Bleed the hydraulic brake system. 7. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (Non-ABS System) Brake Proportioning/Combination Valve: Service and Repair Proportioning Valve Replacement (Non-ABS System) Proportioning Valve Replacement (Non-ABS System) Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure Important: Prior to disconnecting the brake pipes from the proportioning valve assembly, note the locations of the brake pipes to the valve assembly, to aid during installation. 1. Disconnect the caliper and wheel cylinder brake pipes (2) from the proportioning valve assembly. 2. Cap or plug the brake pipe ends to prevent brake fluid loss and contamination. 3. Disconnect the master cylinder brake pipes (1) from the proportioning valve assembly. 4. Cap or plug the brake pipe ends to prevent brake fluid loss and contamination. 5. Remove the master cylinder mounting nuts (1). 6. Remove the proportioning valve assembly from the vehicle. 7. If the proportioning valve is to be reused, plug the brake pipe openings to prevent brake fluid loss and contamination. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (Non-ABS System) > Page 4097 1. Remove the plugs from the proportioning valve assembly. 2. Install the proportioning valve assembly to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the master cylinder mounting nuts (1). ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 4. Remove the caps or plugs from the master cylinder brake pipe ends. 5. Connect the master cylinder brake pipes (1) to the proportioning valve assembly. 6. Tighten the brake pipe fittings at the proportioning valve assembly. ^ Tighten the fittings to 23 Nm (17 ft. lbs.). 7. Remove the caps or plugs from the caliper and wheel cylinder brake pipe ends. 8. Connect the caliper and wheel cylinder brake pipes (2) to the proportioning valve assembly. 9. Tighten the brake pipe fittings at the proportioning valve assembly. ^ Tighten the fittings to 23 Nm (17 ft. lbs.). 10. Bleed the hydraulic brake system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Proportioning Valve Replacement (Non-ABS System) > Page 4098 Brake Proportioning/Combination Valve: Service and Repair Proportioning Valve Replacement (ABS System) Proportioning Valve Replacement (ABS System) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Using a backup wrench, disconnect the brake lines (2) from the proportioning valves (1), and remove the valve assemblies (1). 3. Cap or plug the brake pipe ends to prevent brake fluid loss and contamination. Installation Procedure 1. Remove the caps or plugs from the brake pipe ends. 2. Install the proportioning valves (1). Notice: Refer to Fastener Notice in Service Precautions. 3. Connect the brake pipe fittings (2) at the in-line proportioning valves (1). ^ Tighten the fittings to 27 Nm (20 ft. lbs.). 4. Bleed the hydraulic brake system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Brake Pressure Modulator Valve (BPMV) Bracket Replacement Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the EBCM/BPMV assembly to mounting bracket bolt. 3. Without disconnecting any brake pipes, remove the EBCM/BPMV assembly from mounting bracket, then carefully reposition and support the modulator assembly to provide access for bracket removal. 4. Remove the master cylinder mounting nuts. 5. Remove the BPMV bracket from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 4103 1. Install the BPMV bracket into position in the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the master cylinder mounting nuts. ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 3. Install the EBCM/BPMV assembly to the mounting bracket. 4. Install the EBCM/BPMV assembly to mounting bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 4104 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Brake Pressure Modulator Valve (BPMV) Replacement Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Clean the Brake Pressure Modulator Valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material. 3. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material. 4. Disengage the electrical Connector Position Assurance (CPA) locking tab (1) from the connector sliding cover lock tab. 5. Depress the cover lock tab, then move the sliding connector cover (2) to the open position. 6. Disconnect the electrical connector from the EBCM. Important: Prior to disconnecting the brake pipes from the ABS modulator assembly, note the locations of the brake pipes to the valve assembly, to aid during installation. 7. Disconnect the caliper and wheel cylinder brake pipes (2) from the BPMV. 8. Cap the brake pipe ends to prevent brake fluid loss and contamination. 9. Plug the brake pipe ports on the BPMV to prevent fluid loss and contamination. 10. Carefully reposition the caliper and wheel cylinder brake pipes (2) to gain access to the master cylinder pipes (1). 11. Disconnect the master cylinder brake pipes (1) from the BPMV. 12. Cap the brake pipe ends to prevent brake fluid loss and contamination. 13. Plug the brake pipe ports on the BPMV to prevent fluid loss and contamination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 4105 14. Remove the EBCM/BPMV assembly to mounting bracket bolt. 15. Remove the EBCM/BPMV assembly from the vehicle. 16. Remove the 4 EBCM-to-BPMV retaining bolts. Important: ^ Do not pry apart the EBCM (1) from the BPMV (2) using a tool. Be careful not to damage seal on the EBCM or the mating surface of the BPMV. ^ Care must be taken not to damage the solenoids when the EBCM is removed from the BPMV. 17. Separate the EBCM (1) from the BPMV (2) by carefully pulling apart. Installation Procedure Important: When installing a new brake modulator assembly, do NOT remove the shipping plugs from the pipe ports until after installation into the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 4106 1. Clean the seal and sealing surface of the EBCM, with denatured alcohol and a clean shop cloth. 2. If the BPMV that was removed is being reinstalled, clean the sealing surface of the BPMV, with denatured alcohol and a clean shop cloth. 3. Install the EBCM (1) to the BPMV (2). Use care when aligning the EBCM to the BPMV electrical terminals. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 EBCM-to-BPMV retaining bolts. Tighten the bolts in a cries-cross pattern. ^ Tighten the bolts to 5 Nm (44 inch lbs.). 5. Install the EBCM/BPMV assembly to the mounting bracket. 6. Install the EBCM/BPMV assembly to mounting bracket bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 7. Remove the caps from the master cylinder brake pipe ends Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 4107 8. Remove the plugs from the master cylinder ports on the BPMV. 9. Connect the master cylinder brake pipes (1) to the BPMV, in the same location as removed. 10. Tighten the brake pipe fittings at the BPMV. ^ Tighten the fittings to 24 Nm (18 ft. lbs.). 11. Remove the caps from the caliper and wheel cylinder brake pipe ends. 12. Remove the plugs from the caliper and wheel cylinder ports on the BPMV. 13. Connect the caliper and wheel cylinder brake pipes (2) to the BPMV, in the same location as removed. 14. Tighten the brake pipe fittings at the BPMV. ^ Tighten the fittings to 24 Nm (18 ft. lbs.). 15. Connect the electrical harness connector (4) to the EBCM (3). 16. Depress the cover lock tab, then move the sliding connector cover (2) to the home position to lock. 17. Engage the electrical connector CPA locking tab (1) to the connector sliding cover lock tab. 13. Perform the ABS Automated Bleed Procedure. Important: Do NOT start the engine, but only turn the ignition switch to the ON position. 19. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 115, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4112 Brake Master Cylinder: Service and Repair Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector (3) from the brake fluid level sensor. 2. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1), and press the sensor through the reservoir (2) to remove. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4113 1. Install the brake fluid level sensor to the master cylinder reservoir. Press the sensor into place to secure the sensor retaining tabs. 2. Connect the electrical connector (3) to the brake fluid level sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4114 Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4115 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4116 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Disconnect the electrical connector (3) from the brake fluid level sensor. 2. Disconnect the brake pipes (4) from the master cylinder (1). 3. Cap the open brake pipes (4) to prevent brake fluid loss and contamination. 4. Remove the master cylinder mounting nuts (2). 5. Move the proportioning valve assembly bracket or the antilock brake modulator bracket forward, just enough to clear the studs on the brake booster. 6. Remove the master cylinder (1) from the booster (5). Installation Procedure 1. Bench bleed the master cylinder. 2. Install the master cylinder (1) to the vacuum brake booster (5). 3. Position the proportioning valve assembly bracket or the antilock brake modulator bracket, onto the brake booster studs. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the master cylinder mounting nuts (2). ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 5. Remove the caps from brake pipes (4). 6. Connect the brake pipe fittings (4) at the master cylinder (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4117 ^ Tighten the fittings to 23 Nm (17 ft. lbs.). 7. Connect the electrical connector (3) to the brake fluid level sensor. 8. Bleed the hydraulic brake system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4118 Brake Master Cylinder: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 115, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Fluid Level Sensor Replacement Master Cylinder Fluid Level Sensor Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4119 1. Disconnect the electrical connector (3) from the brake fluid level sensor. 2. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1), and press the sensor through the reservoir (2) to remove. Installation Procedure 1. Install the brake fluid level sensor to the master cylinder reservoir. Press the sensor into place to secure the sensor retaining tabs. 2. Connect the electrical connector (3) to the brake fluid level sensor. Master Cylinder Overhaul Master Cylinder Overhaul Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4120 Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4121 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Master Cylinder Replacement Master Cylinder Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Disconnect the electrical connector (3) from the brake fluid level sensor. 2. Disconnect the brake pipes (4) from the master cylinder (1). 3. Cap the open brake pipes (4) to prevent brake fluid loss and contamination. 4. Remove the master cylinder mounting nuts (2). 5. Move the proportioning valve assembly bracket or the antilock brake modulator bracket forward, just enough to clear the studs on the brake booster. 6. Remove the master cylinder (1) from the booster (5). Installation Procedure 1. Bench bleed the master cylinder. 2. Install the master cylinder (1) to the vacuum brake booster (5). 3. Position the proportioning valve assembly bracket or the antilock brake modulator bracket, onto the brake booster studs. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4122 4. Install the master cylinder mounting nuts (2). ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 5. Remove the caps from brake pipes (4). 6. Connect the brake pipe fittings (4) at the master cylinder (1). ^ Tighten the fittings to 23 Nm (17 ft. lbs.). 7. Connect the electrical connector (3) to the brake fluid level sensor. 8. Bleed the hydraulic brake system. Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Remove the master cylinder from the vehicle. 2. Secure the master cylinder in a vise. Do not clamp the master cylinder body' secure only at the flange. 3. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1), and press the sensor through the reservoir (2) to remove. 4. Carefully tap out the reservoir retaining pins. 5. Remove the reservoir from the from the master cylinder by pulling the reservoir straight up and away from the cylinder. 6. Remove the seals from the master cylinder. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4123 1. Inspect the reservoir (1) for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals (2) and outer surface area of the reservoir-to-housing barrels with Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT 3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals (2). make sure they fully seated. 6. Install the reservoir (1) to the master cylinder, by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully tap the reservoir retaining pins into place to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vise. 10. Install the master cylinder to the vehicle. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bench Bleeding > Page 4124 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4129 Wheel Cylinder: Service and Repair Wheel Cylinder Replacement ^ Tools Required J 38400 Brake Shoe Spanner and Spring Remover Caution: Refer to Brake Dust Caution in Service Precautions. Caution: Refer to Brake Fluid Irritant Caution in Service Precautions. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake drum. 4. Clean any debris and contaminants from around the wheel cylinder. 5. Remove the wheel cylinder bleeder cap and valve (2). 6. Disconnect the brake pipe fitting (1) from the wheel cylinder. Cap the exposed brake pipe end to prevent fluid loss and contamination. 7. Remove the wheel cylinder mounting bolts (3). 8. Using the J 38400, spread the top of the brake shoes apart, then remove the wheel cylinder from the brake backing plate. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Page 4130 1. Using the J 38400, spread the top of the brake shoes apart, then install the wheel cylinder to the brake backing plate. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the wheel cylinder mounting bolts (3). ^ Tighten the bolts to 16 Nm (12 ft. lbs.). 3. Remove the cap from the brake pipe end. 4. Connect the brake pipe fitting (1) at the wheel cylinder. ^ Tighten the fitting to 18 Nm (13 ft. lbs.). 5. Install the wheel cylinder bleeder valve. ^ Tighten the valve to 8 Nm (71 inch lbs.). 6. Install the brake drum. 7. Bleed the hydraulic brake system. 8. Install the bleeder valve cap. 9. Adjust the drum brakes. 10. Install the tire and wheel assembly. 11. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front ^ Tools Required J 37043 Parking Brake Cable Release Tool Removal Procedure 1. Remove the floor console. 2. Release the tension from the park brake cable system. 3. Remove the front park brake cable end (3) from the lever reel assembly. 4. Using the J 37043, release the cable conduit end fitting (4) from the lever assembly (2). 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Release the front cable (3) end from the right cable connector (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4136 7. Disconnect the front cable (3) conduit end fitting from the cable equalizer (1). 8. Release the front cable from the retaining strap along the left side of the axle. 9. Remove the front cable guide retaining bolt. 10. Release the front cable pass-thru grommet from the vehicle underbody. 11. Lower the vehicle. 12. Remove the rear seat cushion. 13. Remove the left side carpet retainer. 14. Reposition the carpet for access to the cable. 15. Release the cable from the retaining clip on the floor pan. 16. Remove the front cable from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4137 1. Install the front park brake cable into the vehicle. 2. Position the cable through the pass-thru opening to the vehicle underbody. 3. Install the cable pass-thru grommet to the vehicle floor pan. Ensure that the grommet is fully seated. 4. Secure the cable to the retaining clip on the floor pan. 5. Install the carpet back into position. 6. Install the left side carpet retainer. 7. Install the rear seat cushion. 8. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the front park brake cable guide retaining bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 10. Secure the front cable into the retaining strap along the left side of the axle. 11. Connect the front cable (3) conduit end fitting to the cable equalizer (1). 12. Secure the front cable (3) end to the right cable connector (1). 13. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4138 14. Install the front park brake cable to the lever assembly (2). Ensure that the conduit end fitting (4) is properly secured to the lever assembly. 15. Install the cable end (3) to the lever reel assembly. 16. Restore the tension to the park brake cable system. 17. Install the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4139 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Left Rear Park Brake Cable Replacement - Left Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the left rear cable end (4) from the cable equalizer (1). 4. Release the park brake cable conduit end fitting (1) from the axle bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4140 5. Remove the left rear tire and wheel assembly. 6. Remove the brake drum. 7. Using a flat-bladed screwdriver, depress the visible retaining tab on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. 8. Rotate the park brake cable to expose the other retaining tab. 9. Using a flat-bladed screwdriver, depress the remaining retaining tab on the park brake cable fitting, and release the cable fitting from the backing plate. 10. Move the majority of the cable return spring back through the opening in the backing plate. 11. Push the cable toward the rear of the vehicle, just enough to clear the cable end from the slot on the park brake lever. 12. Using a flat-bladed screwdriver, lift the cable to fully release the cable from the lever, then remove the cable. Installation Procedure 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the cable forward toward the rear of the vehicle, along the outside of the secondary brake shoe, until the cable end is positioned just past the slot on the park brake lever. 3. While holding the cable in position from front to rear, move the cable end to the back of the park brake lever. 4. Press the cable down into the slot on the lever, then pull the cable forward to the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Install the brake drum. 9. Install the left rear tire and wheel assembly. 10. Secure the park brake cable conduit end fitting (1) to the axle bracket. 11. Press the cable firmly to secure the cable conduit end fitting to the axle bracket. Attempt to pull the cable away from the bracket to ensure that the cable is properly seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4141 12. Secure the cable end (4) to the cable equalizer (1). 13. Lower the vehicle. Refer to Vehicle Lifting. 14. Restore the tension to the park brake cable system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4142 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Right Rear Park Brake Cable Replacement - Right Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the right rear cable (2) end from the front cable connector (1). 4. Release the park brake cable conduit end fitting (1) from the axle bracket (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4143 5. Remove the right rear tire and wheel assembly. 6. Remove the brake drum. 7. Using a flat-bladed screwdriver, depress the visible retaining tab (1) on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. 8. Rotate the park brake cable to expose the other retaining tab. 9. Using a flat-bladed screwdriver, depress the remaining retaining tab on the park brake cable fitting, and release the cable fitting from the backing plate. 10. Move the majority of the cable return spring back through the opening in the backing plate. 11. Push the cable toward the rear of the vehicle, just enough to clear the cable end from the slot on the park brake lever. 12. Using a flat-bladed screwdriver, lift the cable to fully release the cable from the lever, then remove the cable. Installation Procedure 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the cable forward toward the rear of the vehicle, along the outside of the secondary brake shoe, until the cable end is positioned just past the slot on the park brake lever. 3. While holding the cable in position from front to rear, move the cable end to the back of the park brake lever. 4. Press the cable down into the slot on the lever, then pull the cable forward to the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Install the brake drum. 9. Install the right rear tire and wheel assembly. 10. Secure the park brake cable conduit end fitting (1) to the axle bracket (2). 11. Press the cable firmly to secure the cable conduit end fitting to the axle bracket. Attempt to pull the cable away from the bracket to ensure that the cable is properly seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4144 12. Secure the cable (2) end to the cable equalizer (1). 13. Lower the vehicle. Refer to Vehicle Lifting. 14. Restore the tension to the park brake cable system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4145 Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the left rear cable end (4) from the cable equalizer (1). 4. Release the front cable (3) conduit end fitting from the cable equalizers) Installation Procedure 1. Secure the front cable (3) conduit end fitting to the cable equalizer (1) 2. Secure the left rear cable end (4) to the cable equalizer (1). 3. Lower the vehicle. 4. Restore the tension to the park brake cable system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4146 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front ^ Tools Required J 37043 Parking Brake Cable Release Tool Removal Procedure 1. Remove the floor console. 2. Release the tension from the park brake cable system. 3. Remove the front park brake cable end (3) from the lever reel assembly. 4. Using the J 37043, release the cable conduit end fitting (4) from the lever assembly (2). 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Release the front cable (3) end from the right cable connector (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4147 7. Disconnect the front cable (3) conduit end fitting from the cable equalizer (1). 8. Release the front cable from the retaining strap along the left side of the axle. 9. Remove the front cable guide retaining bolt. 10. Release the front cable pass-thru grommet from the vehicle underbody. 11. Lower the vehicle. 12. Remove the rear seat cushion. 13. Remove the left side carpet retainer. 14. Reposition the carpet for access to the cable. 15. Release the cable from the retaining clip on the floor pan. 16. Remove the front cable from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4148 1. Install the front park brake cable into the vehicle. 2. Position the cable through the pass-thru opening to the vehicle underbody. 3. Install the cable pass-thru grommet to the vehicle floor pan. Ensure that the grommet is fully seated. 4. Secure the cable to the retaining clip on the floor pan. 5. Install the carpet back into position. 6. Install the left side carpet retainer. 7. Install the rear seat cushion. 8. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Fastener Notice in Service Precautions. 9. Install the front park brake cable guide retaining bolt. ^ Tighten the bolt to 10 Nm (89 inch lbs.). 10. Secure the front cable into the retaining strap along the left side of the axle. 11. Connect the front cable (3) conduit end fitting to the cable equalizer (1). 12. Secure the front cable (3) end to the right cable connector (1). 13. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4149 14. Install the front park brake cable to the lever assembly (2). Ensure that the conduit end fitting (4) is properly secured to the lever assembly. 15. Install the cable end (3) to the lever reel assembly. 16. Restore the tension to the park brake cable system. 17. Install the floor console. Park Brake Cable Replacement - Left Rear Park Brake Cable Replacement - Left Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the left rear cable end (4) from the cable equalizer (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4150 4. Release the park brake cable conduit end fitting (1) from the axle bracket. 5. Remove the left rear tire and wheel assembly. 6. Remove the brake drum. 7. Using a flat-bladed screwdriver, depress the visible retaining tab on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. 8. Rotate the park brake cable to expose the other retaining tab. 9. Using a flat-bladed screwdriver, depress the remaining retaining tab on the park brake cable fitting, and release the cable fitting from the backing plate. 10. Move the majority of the cable return spring back through the opening in the backing plate. 11. Push the cable toward the rear of the vehicle, just enough to clear the cable end from the slot on the park brake lever. 12. Using a flat-bladed screwdriver, lift the cable to fully release the cable from the lever, then remove the cable. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4151 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the cable forward toward the rear of the vehicle, along the outside of the secondary brake shoe, until the cable end is positioned just past the slot on the park brake lever. 3. While holding the cable in position from front to rear, move the cable end to the back of the park brake lever. 4. Press the cable down into the slot on the lever, then pull the cable forward to the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Install the brake drum. 9. Install the left rear tire and wheel assembly. 10. Secure the park brake cable conduit end fitting (1) to the axle bracket. 11. Press the cable firmly to secure the cable conduit end fitting to the axle bracket. Attempt to pull the cable away from the bracket to ensure that the cable is properly seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4152 12. Secure the cable end (4) to the cable equalizer (1). 13. Lower the vehicle. Refer to Vehicle Lifting. 14. Restore the tension to the park brake cable system. Park Brake Cable Replacement - Right Rear Park Brake Cable Replacement - Right Rear Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the right rear cable (2) end from the front cable connector (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4153 4. Release the park brake cable conduit end fitting (1) from the axle bracket (2). 5. Remove the right rear tire and wheel assembly. 6. Remove the brake drum. 7. Using a flat-bladed screwdriver, depress the visible retaining tab (1) on the park brake cable fitting, then tilt the released side of the cable end back into the backing plate. 8. Rotate the park brake cable to expose the other retaining tab. 9. Using a flat-bladed screwdriver, depress the remaining retaining tab on the park brake cable fitting, and release the cable fitting from the backing plate. 10. Move the majority of the cable return spring back through the opening in the backing plate. 11. Push the cable toward the rear of the vehicle, just enough to clear the cable end from the slot on the park brake lever. 12. Using a flat-bladed screwdriver, lift the cable to fully release the cable from the lever, then remove the cable. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4154 1. Insert the park brake cable through the opening in the backing plate. Only install the cable return spring to just rearward of the spring positioning tab on the backing plate. 2. Push the cable forward toward the rear of the vehicle, along the outside of the secondary brake shoe, until the cable end is positioned just past the slot on the park brake lever. 3. While holding the cable in position from front to rear, move the cable end to the back of the park brake lever. 4. Press the cable down into the slot on the lever, then pull the cable forward to the front of the vehicle to secure the cable end to the slot. 5. While continuing to pull the cable away from the lever, insert a flat-bladed screwdriver into the opening on the lever to prevent the cable from lifting out of the slot on the lever. 6. Move the cable return spring through the opening in the backing plate. 7. Secure the cable fitting to the backing plate. Attempt to pull the park brake cable free of the backing plate, to ensure that the retaining tabs (1) on the fitting are properly secured. 8. Install the brake drum. 9. Install the right rear tire and wheel assembly. 10. Secure the park brake cable conduit end fitting (1) to the axle bracket (2). 11. Press the cable firmly to secure the cable conduit end fitting to the axle bracket. Attempt to pull the cable away from the bracket to ensure that the cable is properly seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4155 12. Secure the cable (2) end to the cable equalizer (1). 13. Lower the vehicle. Refer to Vehicle Lifting. 14. Restore the tension to the park brake cable system. Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Release the tension from the park brake cable system. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Release the left rear cable end (4) from the cable equalizer (1). 4. Release the front cable (3) conduit end fitting from the cable equalizers) Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4156 1. Secure the front cable (3) conduit end fitting to the cable equalizer (1) 2. Secure the left rear cable end (4) to the cable equalizer (1). 3. Lower the vehicle. 4. Restore the tension to the park brake cable system. Disabling the Park Brake Cable Automatic Adjuster Disabling the Park Brake Cable Automatic Adjuster 1. Remove the floor console. 2. Ensure that the park brake lever assembly is fully released. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Have an assistant pull and hold the front park brake cable (3) toward the rear of the vehicle to cause the ratcheting cam of the park brake lever assembly to rotate backwards, against the clock spring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4157 5. Have the assistant pull the front cable until the notch on the ratcheting cam (1) is visible through the opening in the cam cover plate (4). 6. Push the pawl spring (5) downward toward the notch on the ratcheting cam (1). 7. Have the assistant slowly release the cable to allow the notch on the cam (1) to catch the leg of the spring (5). Enabling the Park Brake Cable Automatic Adjuster Enabling the Park Brake Cable Automatic Adjuster 1. Have an assistant pull and hold the front park brake cable (3) toward the rear of the vehicle to cause the ratcheting cam of the park brake lever assembly to rotate backwards, against the clock spring. 2. Have the assistant pull the front cable (3) until the notch on the ratcheting cam (1) is released from the pawl spring (5). 3. Have the assistant slowly release the cable to allow the cam (1) to coil properly. 4. Fully apply and release the park brake lever 4 - times to restore tension to the park brake cable system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 4158 5. Lower the vehicle. 6. Install the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Park Brake Lever Assembly Replacement ^ Tools Required J 37043 Parking Brake Cable Release Tool Removal Procedure 1. Remove the floor console. 2. Release the tension from the park brake cable system. 3. Disconnect the electrical connector (1) from the park brake warning lamp switch. 4. Remove the front park brake cable end (3) from the lever reel assembly. 5. Using the J 37043, release the cable conduit end fitting (4) from the lever assembly (2). 6. Remove the transmission shift control assembly mounting nuts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 4162 7. Remove the park brake lever assembly rear mounting nut. 8. Raise the shift control assembly just enough to allow the park brake lever assembly (6) to be removed. 9. Remove the console attachment bracket. 10. Remove the lever assembly (6). Installation Procedure 1. Install the park brake lever assembly (6) into position. 2. Install the console attachment bracket. 3. Install the transmission shift control assembly into position. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 4163 4. Install the transmission shift control assembly mounting nuts. ^ Tighten the nuts to 25 Nm (18 ft. lbs.). 5. Install the park brake lever assembly rear mounting nut. ^ Tighten the nut to 25 Nm (18 ft. lbs.). 6. Install the front park brake cable to the lever assembly (2). Ensure that the conduit end fitting (4) is properly secured to the lever assembly. 7. Install the cable end (3) to the lever reel assembly. 8. Connect the electrical connector (1) to the park brake warning lamp switch 9. Restore the tension to the park brake cable system. 10. Install the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement Removal Procedure 1. Remove the air cleaner assembly. 2. Remove the master cylinder mounting nuts (10). 3. Move the master cylinder and the proportioning valve assembly or the antilock brake modulator assembly forward just enough in order to clear the studs on the brake booster. This flexes the brake pipes slightly. Do not bend or distort the brake pipes. 4. Remove the vacuum hose from the vacuum check valve. 5. Remove the brake booster mounting nuts (7). 6. Remove the retaining clip (1) and washer (2) from the brake pedal. 7. Disconnect the brake booster pushrod (3) from the brake pedal. Tilt the entire brake booster slightly in order to work the booster pushrod off the pedal clevis pin without putting undue pressure on the pushrod. 8. Remove the booster from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 4171 1. Install the brake booster to the vehicle. 2. Ensure that the inner washer (4) is in position on the brake pedal. 3. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal. 4. Connect the brake booster pushrod (3) to the brake pedal. Tilt the entire brake booster slightly in order to work the booster pushrod onto the pedal clevis pin without putting undue pressure on the pushrod. 5. Install the outer washer (2) and retaining clip (1) to the brake pedal. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the vacuum brake booster mounting nuts (7). ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 7. Install the vacuum hose to the vacuum check valve. 8. Move the master cylinder (11) and the proportioning valve assembly or the antilock brake modulator assembly onto the brake booster (9) studs. 9. Install the master cylinder mounting nuts (10). ^ Tighten the nuts to 27 Nm (20 ft. lbs.). 10. Install the air cleaner assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Disconnect the brake booster vacuum check valve (1) from the brake booster. 2. If the vacuum check valve (1) needs to be separated from the vacuum hose (3), release and reposition the clamp (2) on the vacuum hose (3) and remove the check valve (1) from the hose (3). 3. If replacing the vacuum check valve (1), remove the grommet from the brake booster and discard the grommet. 4. If replacing the vacuum hose, release the vacuum hose connector retainer (1), then disconnect the connector from the vacuum port on the engine intake manifold. Take note of the vacuum hose routing, then remove the vacuum hose from the vehicle. Installation Procedure Important: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve and/or grommet. Do NOT use soap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair > Page 4175 1. If the vacuum hose was removed, install the vacuum hose into position on the vehicle' as noted prior to removal. 2. If the vacuum hose was removed, connect the vacuum hose connector to the vacuum port on the intake manifold. Press the connector retainer (1) down firmly to secure the connector to the port. 3. If the vacuum check valve (1) is being replaced, install a NEW grommet to the brake booster. 4. If the vacuum check valve (1) was separated from the vacuum hose (3), install the check valve (1) to the vacuum hose (3). Install and secure the clamp (2) into position on the hose (3). 5. Connect the brake booster vacuum check valve (1) to the brake booster. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position 2. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area of any accumulated dirt and foreign material. 3. Disengage the electrical Connector Position Assurance (CPA) locking tab (1) from the connector sliding cover lock tab. 4. Depress the cover lock tab, then move the sliding connector cover (2) to the open position. 5. Disconnect the electrical harness connector (4) from the EBCM (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Page 4180 6. Remove the 4 EBCM-to-BPMV retaining bolts. Important: ^ Do not pry apart the EBCM (1) from the BPMV (2) using a tool. Be careful not to damage seal on the EBCM or the mating surface of the BPMV. ^ Care must be taken not to damage the solenoids when the EBCM is removed from the BPMV. 7. Separate the EBCM (1) from the BPMV (2) by carefully pulling apart. Installation Procedure 1. Clean the sealing surface of the BPMV, with denatured alcohol and a clean shop cloth. 2. If the EBCM that was removed is being reinstalled, clean the seal and sealing surface of the EBCM, with denatured alcohol and a clean shop cloth. 3. Install the EBCM (1) to the BPMV (2). Use care when aligning the EBCM to the BPMV electrical terminals. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the 4 EBCM-to-BPMV retaining bolts. Tighten the bolts in a cries-cross pattern. ^ Tighten the bolts to 5 Nm (44 inch lbs.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Page 4181 5. Connect the electrical harness connector (4) to the EBCM (3). 6. Depress the cover lock tab, then move the sliding connector cover (2) to the home position to lock. 7. Engage the electrical connector CPA locking tab (1) to the connector sliding cover lock tab. Important: Do NOT start the engine, but only turn the ignition switch to the ON position. 8. Perform the ABS Diagnostic System Check. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement Removal Procedure 1. Carefully remove the instrument panel dimmer switch bezel from the dash. 2. Disconnect the electrical connector from the traction control switch. 3. Remove the traction control switch from the instrument panel dimmer switch bezel. To avoid damage to the instrument panel dimmer switch bezel, use a flat bladed tool on the back side of the traction control switch to release the retaining clips. Installation Procedure 1. Install the traction control switch to the instrument panel dimmer switch bezel. 2. Connect the electrical connector to the traction control switch. 3. Align the instrument panel dimmer switch bezel to the dash and carefully press the retaining clips into the correct mounting areas on the dash. 4. Verify the repair. Refer to Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: Customer Interest ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Customer Interest for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 4197 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Wheel Speed Sensor: All Technical Service Bulletins ABS - Warning Lamp ON/DTC's C1223 and C1225 Set Bulletin No.: 04-05-25-007 Date: May 26, 2004 TECHNICAL Subject: ABS Warning Light On, Traction Off Warning Light On, DTCs C1223 and C1225 Set (Replace Left Front ABS Wheel Speed Sensor Jumper Harness) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire Condition Some customers may comment that the ABS warning light and/or Traction Off warning light is illuminated. Upon investigation, the technician may find ABS codes (C1223 - C1225) set as intermittent or hard failures. Cause The cause of this condition may be the front wheel speed sensor jumper harness. The harness may check good with the voltmeter, but will not function correctly when subjected to suspension movement, vibration, and flexing. Correction Visually inspect the left front ABS wheel speed sensor harness connector. The wires may become unseated from the connector. This is especially important on the left side. If the wiring is faulty, replace the harness using the procedure listed below. 1. Raise and support the vehicle. 2. Unclip the 3 forward harness routing clips. These clips will be used on the new harness. 3. Remove the remaining 2 harness routing clips from the control arm. The new harness includes these 2 clips for locating purposes. 4. Disconnect the wheel speed sensor connector. 5. Route the new harness into position and install clips. 6. On the old harness, cut the tape, pull back the conduit, and cut the wire harness to length. 7. Strip the wire ends, splice the wires using the provided splice clips. Put back in conduit and tape. 8. Lower the vehicle. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Speed Sensor: > 04-05-25-007 > May > 04 > ABS - Warning Lamp ON/DTC's C1223 and C1225 Set > Page 4203 For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4204 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Caution: Refer to Brake Dust Caution in Service Precautions. Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the front wheel speed sensor. 3. Remove the wheel speed sensor retaining bolt. 4. Remove the wheel speed sensor from the steering knuckle. If the sensor will not slide out of the knuckle perform the following steps: 4.1. Remove the brake rotor to access the other side of the knuckle. 4.2. Using a blunt punch, or equivalent tool, push the sensor from the outboard side of the knuckle. 5. Inspect the removed wheel speed sensor and the steering knuckle to ensure that the sensor's locating pin has not broken off in the locating hole of the knuckle. If the locating pin remains in the locating hole of the knuckle, perform the following steps. 5.1. Remove the brake rotor, if it has not already been removed, to access the other side of the knuckle. 5.2. Using a blunt punch, or equivalent tool, remove the broken locating pin from the outboard side of the knuckle. 5.3. If necessary, clean the locating hole in the knuckle using sand paper wrapped around a screwdriver, or other suitable tool. Never attempt to enlarge the hole. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 4205 1. Install the front wheel speed sensor to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front wheel speed sensor retaining bolt. ^ Tighten the bolt to 12 Nm (107 inch lbs.). 3. Connect the electrical connector to the front wheel speed sensor. 4. Lower the vehicle. 5. Perform the Diagnostic System Check - ABS. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. - Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 4211 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery. Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery. Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery. This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE 1. Record all of the vehicle preset radio stations. CAUTION: Refer to SIR Caution in Service Precautions. - Refer to Battery Disconnect Caution in Service Precautions. 2. Turn OFF all the lamps and the accessories. 3. Make sure the ignition switch is in the OFF position. 4. Disconnect the battery negative cable from the battery. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal. Connect the battery negative cable to the battery. Tighten Tighten the bolt to 15 N.m (11 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 4217 Negative: Service and Repair Battery Negative Cable Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove air intake duct and resonator. 3. Cut the tape holding the two cables together at the retainer on the battery tray. 4. Cut the tape holding the two cables together near the transmission electrical plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 4218 5. Remove the wire harness retainer nut at the rear of the engine. 6. Position the wire retainer aside. 7. Remove bolt retaining cable to battery tray. 8. Remove the negative battery cable ground stud from the engine block. 9. Remove the negative battery cable. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 4219 1. Position the new cable in the vehicle. 2. Install the ground stud through the negative cable and into the engine block. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the negative battery cable ground stud to 25 N.m (18 lb ft). 3. Position the engine wire harness retainer onto the ground stud. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 4220 4. Install the wire harness retainer onto the stud. Tighten Tighten the wire harness retainer nut to 18 N.m (13 lb ft). 5. Install the bolt to retain negative battery cable to battery tray. 6. Tape the cables together at the battery tray. 7. Tape the cables together at the transmission electrical plug. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 4221 8. Install air cleaner resonator and outlet duct. 9. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove outlet duct and resonator. 2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable at the battery. 4. Lift fuse/relay center to access power lead bolt. 5. Remove power lead bolt from fuse/relay center. 6. Cut the tape holding the 2 cables together at the retainer on the battery tray. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 4225 7. Cut the tape holding the 2 cables together near the transmission electrical plug. 8. Remove the positive battery cable to starter solenoid nut. 9. Remove the positive battery cable from the vehicle. INSTALLATION PROCEDURE 1. Position the new cable in the vehicle in the same location as the old cable. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the positive battery cable to the starter solenoid nut. Tighten Tighten the positive battery cable to starter solenoid nut to 17 N.m (13 lb ft). 3. Tape the cables together at the transmission electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 4226 4. Tape the cables together at the battery tray. 5. Install power lead bolt to fuse/relay center. 6. Install fuse/relay center. 7. Install the positive battery cable end onto the battery. Tighten Tighten the battery positive cable terminal bolt to 15 N.m (11 lb ft). 8. Connect the negative battery cable. 9. Install the outlet duct and resonator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Generator Usage Generator Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Generator Usage > Page 4232 Alternator: Specifications Voltage and Amperage Generator Rated Output ...................................................................................................................... .......................................................................... 105 A Load Test Output ........................................... .............................................................................................................................................................. ... 73 A Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 4233 Generator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Connector Views Generator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4236 Alternator: Description and Operation GENERATOR The generator features the following major components: The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - Dual internal fans - The regulator The pulley and the fan cool the slip ring and the frame. The generator features permanently lubricated bearings. Service should only include tightening of mount components. Otherwise, replace the generator as a complete unit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 4237 Alternator: Service and Repair GENERATOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect negative battery cable. 2. Remove the drive belt. 3. Disconnect the electrical connectors from the generator. 4. Remove the generator bolts. 5. Remove the generator. INSTALLATION PROCEDURE 1. Install the generator. 2. Install the generator bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the generator bolts to 20 N.m (15 lb ft). 3. Connect the generator electrical connectors. Tighten Tighten the generator electrical connector to 17 N.m (13 lb ft). 4. Install the drive belt. 5. Lower the vehicle. 6. Connect the battery negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation REGULATOR The voltage regulator controls the rotor field current in order to limit the system voltage. When the field current is on, the regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair IGNITION LOCK ACTUATOR REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/SIR Caution 2. Remove the lock cylinder. 3. Remove the steering column tilt head housing. 4. Remove the 2 tapping screws (1). 5. Remove the lock bolt support bracket (2). 6. Remove the lock bolt assembly (3). 7. Remove the ignition lock actuator assembly (4). INSTALLATION PROCEDURE 1. Install the ignition lock actuator assembly (4). 2. Install the lock bolt assembly (3). 3. Install the lock bolt support bracket (2). 4. Install the 2 tapping screws (1). NOTE:Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 1.5 Nm (13 lb in). 5. Install the steering column tilt head housing. 6. Install the lock cylinder. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 4249 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 4250 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 4251 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4255 Starter Motor Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4256 Starter Motor: Service and Repair STARTER MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to vehicle lifting.. 3. Disconnect the electrical connectors (3,4) from the starter. 4. Remove the starter bolts. 5. Remove the starter. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 4257 1. Install the starter. 2. Install the starter bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the starter bolts to 40 N.m (30 lb ft). 3. Connect the electrical connectors (4) to the starter. Tighten Tighten the battery terminal nut to 17 N.m (13 lb ft). 4. Connect the electrical connectors (3) to the starter. Tighten Tighten the S terminal nut to 3 N.m (27 lb in). 5. Lower the vehicle. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Connector Views Accessory Power Outlet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Connector Views > Page 4263 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4264 Auxiliary Power Outlet: Service and Repair ACCESSORY POWER RECEPTACLE REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power accessory port fuse. 2. Remove the power accessory port access cover. 3. Remove the power accessory port housing by placing one side of the "T" portion of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory port housing straight out. 4. Remove J 42059 from the power accessory port housing. 5. Disconnect the electrical connector from the power accessory port housing. 6. Using your index finger pull out the power accessory port retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4265 7. If the standard method fails to remove the socket, use the following alternate method: 7.1. Insert a small grinding tool (2) with a cutoff wheel into the socket. 7.2. Remove the plastic latches (1) in the 3-mm (0.11-in) square windows. 7.3. Use J 42059 as directed above to remove the socket. IMPORTANT: If tool fails to remove power accessory port. INSTALLATION PROCEDURE 1. Install the power accessory port retainer by pressing the retainer into place until fully seated. 2. Connect the electrical connector to the power accessory port housing. 3. Align the power accessory port housing to the slots in the retainer opening. 4. Install the power accessory port housing to the retainer opening. 5. Press the power accessory port into place until fully seated in the retainer. 6. Install the power accessory port fuse. 7. Inspect the power accessory port for proper operation. 8. Install the power accessory port housing access cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P > Page 4272 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4275 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4276 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4277 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4278 Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4279 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4280 Fuse: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4281 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4282 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4283 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4284 Location View Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4285 Location View Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - I/P > Page 4290 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4293 Fuse Block - I/P Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4294 Fuse Block - I/P Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4295 Fuse Block - I/P Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4296 Fuse Block - I/P Wire Entry Part 5 Fuse Block - Underhood Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4297 Fuse Block - Underhood Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4298 Fuse Block - Underhood Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4299 Fuse Block - Underhood Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4302 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4303 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4304 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4305 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4306 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4307 Fuse Block: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4308 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4309 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4310 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4311 Location View Application Table Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4312 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4313 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4314 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4319 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4320 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4321 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4322 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4323 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4324 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 Multiple Junction Connector: Diagrams C100 - C104 In-line Connector C100 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4329 In-line Connector C100 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4330 In-line Connector C100 Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4331 In-line Connector C100 Part 4 In-line Connector C101 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4332 In-line Connector C101 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4333 In-line Connector C102 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4334 In-Line Connector C103 (Automatic Transmission) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4335 In-Line Connector C103 (Automatic Transmission) Part 2 In-Line Connector C103 (Automatic Transmission) Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4336 In-Line Connector C104 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4337 Multiple Junction Connector: Diagrams C200 - C222 In-Line Connector C200 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4338 In-Line Connector C200 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4339 In-Line Connector C200 Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4340 In-Line Connector C201 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4341 In-Line Connector C202 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4342 In-Line Connector C203 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4343 In-Line Connector C204 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4344 In-Line Connector C206 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4345 In-Line Connector C207 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4346 In-Line Connector C220 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4347 In-Line Connector C221 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4348 In-Line Connector C222 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4349 Multiple Junction Connector: Diagrams C313 In-Line Connector C313 (Wheel Speed Sensors) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4350 In-Line Connector C313 (EVAP Solenoid) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4351 In-Line Connector C313 (Fuel Systems) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 4357 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4360 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4361 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4362 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4363 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4364 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 4369 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4372 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4373 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4374 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4375 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4376 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4385 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4386 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4387 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: Customer Interest A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4392 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4393 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4399 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4400 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4401 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4406 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4407 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4408 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4409 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4410 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4411 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4416 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: All Technical Service Bulletins A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4421 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4422 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4428 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4429 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4430 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4431 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4432 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4433 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4438 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Connector Views Accessory Power Outlet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Connector Views > Page 4444 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4445 Auxiliary Power Outlet: Service and Repair ACCESSORY POWER RECEPTACLE REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power accessory port fuse. 2. Remove the power accessory port access cover. 3. Remove the power accessory port housing by placing one side of the "T" portion of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory port housing straight out. 4. Remove J 42059 from the power accessory port housing. 5. Disconnect the electrical connector from the power accessory port housing. 6. Using your index finger pull out the power accessory port retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 4446 7. If the standard method fails to remove the socket, use the following alternate method: 7.1. Insert a small grinding tool (2) with a cutoff wheel into the socket. 7.2. Remove the plastic latches (1) in the 3-mm (0.11-in) square windows. 7.3. Use J 42059 as directed above to remove the socket. IMPORTANT: If tool fails to remove power accessory port. INSTALLATION PROCEDURE 1. Install the power accessory port retainer by pressing the retainer into place until fully seated. 2. Connect the electrical connector to the power accessory port housing. 3. Align the power accessory port housing to the slots in the retainer opening. 4. Install the power accessory port housing to the retainer opening. 5. Press the power accessory port into place until fully seated in the retainer. 6. Install the power accessory port fuse. 7. Inspect the power accessory port for proper operation. 8. Install the power accessory port housing access cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Block - I/P > Page 4453 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P Fuse: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4456 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4457 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4458 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4459 Fuse: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4460 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4461 Fuse: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4462 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4463 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4464 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4465 Location View Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - I/P > Page 4466 Location View Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Block - I/P > Page 4471 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - I/P Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4474 Fuse Block - I/P Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4475 Fuse Block - I/P Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4476 Fuse Block - I/P Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4477 Fuse Block - I/P Wire Entry Part 5 Fuse Block - Underhood Wire Entry Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4478 Fuse Block - Underhood Wire Entry Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4479 Fuse Block - Underhood Wire Entry Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 4480 Fuse Block - Underhood Wire Entry Part 4 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P Fuse Block: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4483 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4484 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4485 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4486 Fuse Block: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4487 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4488 Fuse Block: Application and ID Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4489 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4490 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4491 Location View Fuse Block - Underhood Label Usage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4492 Location View Application Table Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuse Block - I/P > Page 4493 Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4494 Fuse Block: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Page 4495 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4500 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4501 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4502 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4503 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4504 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 4505 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 Multiple Junction Connector: Diagrams C100 - C104 In-line Connector C100 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4510 In-line Connector C100 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4511 In-line Connector C100 Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4512 In-line Connector C100 Part 4 In-line Connector C101 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4513 In-line Connector C101 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4514 In-line Connector C102 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4515 In-Line Connector C103 (Automatic Transmission) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4516 In-Line Connector C103 (Automatic Transmission) Part 2 In-Line Connector C103 (Automatic Transmission) Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4517 In-Line Connector C104 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4518 Multiple Junction Connector: Diagrams C200 - C222 In-Line Connector C200 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4519 In-Line Connector C200 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4520 In-Line Connector C200 Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4521 In-Line Connector C201 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4522 In-Line Connector C202 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4523 In-Line Connector C203 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4524 In-Line Connector C204 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4525 In-Line Connector C206 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4526 In-Line Connector C207 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4527 In-Line Connector C220 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4528 In-Line Connector C221 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4529 In-Line Connector C222 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4530 Multiple Junction Connector: Diagrams C313 In-Line Connector C313 (Wheel Speed Sensors) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4531 In-Line Connector C313 (EVAP Solenoid) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C100 - C104 > Page 4532 In-Line Connector C313 (Fuel Systems) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 4538 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4541 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4542 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4543 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4544 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4545 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse Block - I/P > Page 4550 Fuse Block - Underhood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P Relay Box: Application and ID Fuse Block - I/P Location View Application Table Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4553 Application Table Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4554 Relay Box: Application and ID Fuse Block - Underhood Fuse Block - Underhood Label Usage Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - I/P > Page 4555 Application Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4556 Relay Box: Service and Repair UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Disconnect the negative battery cable from the battery. 3. Remove the air cleaner mounting bracket. 4. Remove the push-in retainer (3) from the electrical center. 5. Remove the electrical center from the inner fender. 6. Turn the electrical center over and remove the bottom cover. 7. Remove the four plastic wire retainers. 8. Label and remove the wires. NOTE: Note the correct routing of the electrical wiring. Failure to reinstall the wiring properly could result in damage to the wiring. 9. Turn the electrical center right side up and remove the fuses and relays. 10. Remove the electrical center from the vehicle. INSTALLATION PROCEDURE 1. Position the electrical center in the vehicle. 2. Install the fuses and relays. 3. Turn the electrical center over and install the wires. 4. Install the four plastic wire retainers. 5. Install the bottom cover to the electrical center. 6. Install the electrical center to the inner fender. 7. Install the push-in retainer (3) to the electrical center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Page 4557 8. Install the air cleaner mounting bracket. 9. Connect the negative battery cable to the battery. 10. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4566 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4567 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4568 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: Customer Interest A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4573 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4574 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4580 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4581 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4582 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4587 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4588 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4589 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4590 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4591 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4592 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4597 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set Wiring Harness: All Technical Service Bulletins A/T - Slips in 4th Gear/MIL ON/DTC's Set Bulletin No.: 03-07-30-036 Date: August 22, 2003 TECHNICAL Subject: Transmission Slips in 4th Gear, Stuck in 2nd Gear or SES/TCS Light Illuminated, DTCs P0753, P0758, P1860, C1223, C1224 or C1275 May be Set (Repair Conduit Splice/Reposition Conduit or Inspect/Reinstall Evap Emission Vent Solenoid or Replace, if Necessary) Models: 2002-2004 Chevrolet Cavalier 2002-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPL L61) Condition Some customers may comment on an SES/TCS tell-tale light illuminated, the transmission slipping in 4th gear, or the transmission stuck in second gear. DTCs P0753, P0758, P1860, C1223, C1224 or C1275 may be set. Cause There are 2 separate causes that may create the above conditions. Both should be examined when a vehicle is brought in for the above concern. ^ Cause # 1 is possible water intrusion at the transmission to front end vehicle harness. This harness located near the transmission breakout is protected by plastic split tube type conduit and electrical tape. In some cases, the split may be facing upward which will increase the tendency of the conduit to hold water. Eventually, the # 107 splice to the transmission may become corroded and become non-conductive. ^ Cause # 2 can be quickly identified by a visual inspection under the vehicle at the passenger side of the rear axle. The Evaporative Emissions Canister Vent Solenoid retainer may have come loose allowing the associated wire harness to contact the rear axle. Abrasion of the wire against the rear axle may rub through the insulation creating a short. Correction Use one of the two following procedures to correct the above condition. Correction # 1 1. Raise the vehicle. 2. Locate the conduit for the transmission breakout directly above the transmission oil cooler lines. 3. Remove the electrical tape wrap from the plastic conduit and peel the conduit open. 4. With the conduit open, examine the splices inside for signs of corrosion. Splice # 107 (part of circuit 439, PINK) is located approximately 33 cm (13 in) forward of the transmission breakout point. 5. Examine the splice for signs of corrosion. If corrosion is found, repair the splice. Use only a GM Crimp and Seal Splice. 6. Strip back the wire until clean non-corroded wire is available. 7. To resplice the wires, use GM crimp and seal splice, P/N 12089189, only. These connectors are equipped with crimpable joints and heat shrink tubes. 8. Insert the bare wires fully into the body of the connector. 9. Using the J 389125 electrical crimping tool, fully crimp the body of the connector. 10. Using the J 38125-5 Ultratorch, or equivalent, progressively heat the center of the connector and work left until the sealer begins to ooze out. Starting at the center again, work right until sealer oozes out that end. 11. Re-orient the conduit, positioning the split toward the bottom. By repositioning the conduit, you will create a drainage path for the water and eliminate the possibility of the splice corroding again. Retape the conduit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4602 12. Lower the vehicle. 13. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Correction # 2 1. The Evaporative Emissions Vent Solenoid is retained by a molded in, plastic extension. The retainer has molded in ridges that create an interference fit to the underbody. Under some instances, the retainer may have not been fully seated when installed. 2. Remove the jumper harness from the Evaporative Emissions Vent Solenoid. Important: ^ The fastener style used to retain the Evap Vent Solenoid does not provide feedback to the technician in the form of a "click" or detente when properly installed. You should seat the fastener as deeply as possible without using excessive or damaging force. ^ The vent solenoid will not be retained rigidly even when properly installed. 3. Inspect the retainer for damage. Additionally, examine the solenoid body for any signs of damage. If the retainer and solenoid body appear in good condition, reinstall to the underbody cut out. Verify that the fastener holds properly by pulling on the solenoid body to check that it is retained. If the fastener will not retain properly or there are signs of damage, replace the Evap Vent Solenoid. 4. Discard and replace the jumper harness with P/N 12101858. 5. Lower the vehicle. 6. Using the Tech 2(R) Diagnostic Scan Tool, clear all DTCs. Parts Information Parts are currently available at GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 03-07-30-036 > Aug > 03 > A/T - Slips in 4th Gear/MIL ON/DTC's Set > Page 4603 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4609 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4610 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4611 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4612 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4613 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4614 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4619 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4625 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4626 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4627 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4628 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4629 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4630 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 4631 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 4634 Alignment: Specifications Wheel Alignment Specifications WHEEL ALIGNMENT SPECIFICATIONS FRONT SUSPENSION Camber ................................................................................................................................................ ......................................................... -0.20° ± 0.70° Camber Cross..................................................... ............................................................................................................................................. 0.00° ± 0.50° Caster ........................................................................................................................................ ..................................................................... 4.10° ± 0.75° Caster Cross Tolerance ........................... ....................................................................................................................................................... 0.00° ± 0.50° Total Toe ....................................................................................................................... .................................................................................0.10° ± 0.20° Steering Wheel Angle ................... .............................................................................................................................................................. ... 0.00° ± 3.50° REAR SUSPENSION Camber ................................................................................................................................................ ............................................................0.25° ± 0.25° Total Toe ........................................................... .......................................................................................................................................... +0.20° ± 0.20° Thrust Angle ............................................................................................................................... ................................................................... 0.00° ± 0.20° Caster (Nominal -- No means of adjustment provided) Camber Cross Tolerance (Nominal -- No means of adjustment provided) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4635 Alignment: Description and Operation CASTER DESCRIPTION Caster Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. CAMBER DESCRIPTION Camber Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. TOE DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4636 Toe Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. THRUST ANGLES DESCRIPTION The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. LEAD/PULL DESCRIPTION Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: - Tire construction - Uneven brake adjustment - Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. TORQUE STEER DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 4637 A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: - A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. - A large difference in the right and left front tire pressure - Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. MEMORY STEER DESCRIPTION Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. WANDER DESCRIPTION Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. SCRUB RADIUS DESCRIPTION Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Alignment: Service and Repair Trim Height Inspection TRIM HEIGHT INSPECTION PROCEDURE TRIM HEIGHT MEASUREMENTS Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. Refer to Label - Vehicle Certification. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within ± 10 mm (+/-3/8 in) to be considered correct. Z HEIGHT MEASUREMENT The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from bottom surface of the cradle (in line with the ball joint) to the bottom of the lower ball joint in order to obtain the Z height measurement. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications. D HEIGHT MEASUREMENT The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 4640 4. Measure the D height by measuring the distance between the bumper bracket and the top of the rear axle tube. 5. Push the rear bumper downward to 38 mm (1.5 in). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications. 10. If these measurements are out of specifications, inspect for the following conditions: - Improper weight distribution - Collision damage - Worn or damaged suspension components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 4641 Alignment: Service and Repair Measuring Wheel Alignment MEASURING WHEEL ALIGNMENT Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in Tires and Wheels in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: - Inspect the tires for the proper inflation and irregular tire wear. - Inspect the runout of the wheels and the tires. - Inspect the wheel bearings for backlash and excessive play. - Inspect the ball joints and tie rod ends for looseness or wear. - Inspect the control arms and stabilizer shaft for looseness or wear. - Inspect the steering gear for looseness at the frame. - Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. - Inspect the vehicle trim height. - Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. - Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. IMPORTANT:When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. FRONT CASTER ADJUSTMENT The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. FRONT CAMBER ADJUSTMENT 1. Loosen both strut to knuckle nuts just enough to allow for movement. 2. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 2.1. Disconnect the strut from the knuckle. 2.2. File the lower hole until the outer flange slot matches the inner flange slot. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection > Page 4642 2.3. Connect the strut to the knuckle. 3. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 4. Tighten the strut to knuckle nuts to 180 Nm (133 lb ft). FRONT TOE ADJUSTMENT 1. Ensure that the steering wheel is set in a straight ahead position. 2. Loosen the tie rod jam nut (5). 3. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications. 4. Install the tie rod jam nut (5). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 4659 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair STEERING KNUCKLE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the tie rod from the steering knuckle. 4. If the vehicle is equipped with ABS, disconnect the ABS electrical connector. 5. Remove the hub and bearing assembly. 6. Remove the bolts (3) and nuts (6) that attach the steering knuckle (4) to the strut (2). 7. Remove the lower ball joint from the steering knuckle. 8. Remove the steering knuckle (4) from the vehicle. INSTALLATION PROCEDURE 1. Install the steering knuckle (4) to the vehicle. 2. Install the lower ball joint to the steering knuckle. 3. Install the bolts (3) and the nuts (6) attaching the steering knuckle (4) to the strut (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nuts (6) to 180 N.m (133 lb ft). 4. Install the hub and bearing assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Page 4664 5. If the vehicle is equipped with ABS, connect the ABS electrical connector. 6. Install the tie rod to the steering knuckle. 7. Install the tire and wheel assemblies. 8. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair BLEEDING THE POWER STEERING SYSTEM TOOLS REQUIRED - J 35555 Metal Mityvac - J 43485 Power Steering Bleeder Adapter 1. Verify that the hoses do not touch any other part of the vehicle. IMPORTANT:Hoses touching the frame, body, or engine may cause system noise. 2. Verify that all hose connections are tight. IMPORTANT:Loose connections may not leak, but could allow air into the steering system. 3. Remove the pump reservoir cap. NOTE: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. IMPORTANT:Maintain the fluid level throughout the bleed procedure. 4. Fill the pump reservoir with fluid to the FULL COLD level. IMPORTANT:Use clean, new power steering fluid only. 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 in Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7-10 kPa (2-3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis at the end of this procedure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 4669 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. 11. Start the engine. Allow the engine to idle. 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. 14. Start the engine. Allow the engine to idle. IMPORTANT:Do not turn steering wheel to lock. 15. Turn the steering wheel 180-360 degrees in both directions 5 times. 16. Switch the ignition off. 17. Verify the fluid level. NOTE: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 18. Remove the pump reservoir cap. 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 in Hg) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 4670 25. Reinstall the pump reservoir cap. EXCESSIVE VACUUM DROP DIAGNOSIS 1. If the vacuum continues to drop, remove the pressure and return hose from the pump. 2. Install the plugs (1,2) supplied with the J 43485 into the pressure and return port. 3. Attach the J 43485 to the J 35555 or equivalent. 4. Place the J 43485 on or in the pump reservoir filler neck. 5. Apply a vacuum of 68 kPa (20 in Hg) maximum. 6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system. 7. Observe the fluid. IMPORTANT:Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose. Fluid must be free from discoloration. 8. If condition persists, replace the following parts: - The return hose clamps - The return hose O-rings - The pressure hose O-rings - The gear cylinder line O-rings Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 4671 - The reservoir to pump O-ring 9. Repeat the bleed procedure from the beginning. 10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface. 11. Verify the following conditions: - There is smooth power assist. - The vehicle operates quietly. - The pump maintains the proper fluid level. - There is not any leaking in the steering system. - The fluid is free of foam or discoloration. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering System ....................................................................................................................... .................................................. 0.70 liters (1.5 pints) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 4676 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations Power Steering Pump Assembly-CB Series Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 4680 Power Steering Pump Assembly-CB Series Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 4681 Power Steering Fluid Reservoir: Service and Repair POWER STEERING RESERVOIR REPLACEMENT - OFF VEHICLE (CB SERIES) DISASSEMBLY PROCEDURE 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or inside the hydraulic pump housing (1). Discard the O-ring seal. ASSEMBLY PROCEDURE 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Locations Rack And Pinion System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe Power Steering Line/Hose: Service and Repair Power Steering - Pressure Pipe POWER STEERING PRESSURE PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the power steering pressure hose (3) from the power steering pressure pipe (4). 2. Remove the bolt (2) from the power steering pressure pipe bracket (3). 3. Remove the power steering pressure pipe (4) from the power steering pump (1). 4. Remove the power steering pressure pipe (4) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 4687 1. Install the power steering pressure pipe (4) to the vehicle. 2. Install the power steering pressure pipe (4) to the power steering pump (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the bolt (2) to the power steering pressure pipe bracket (3). Tighten Tighten the bolt to 26 N.m (19 lb ft). 4. Install the power steering pressure hose (3) to the power steering pressure pipe (4). Tighten Tighten the fitting to 27 N.m (20 lb ft). 5. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 4688 Power Steering Line/Hose: Service and Repair Power Steering - Pressure Hose POWER STEERING PRESSURE HOSE REPLACEMENT (WITH RPO CODE 2.2L (L61)) REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the front exhaust pipe, automatic transmission only. 3. Remove the power steering pressure hose (1) from the power steering gear (3). 4. Lower the vehicle. 5. Remove the upper air cleaner assembly. 6. Remove the power steering pressure hose (3) from the power steering pump pipe (4). 7. Remove the power steering pressure hose (3) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 4689 1. Install the power steering pressure hose (3) to the vehicle. NOTE: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Installing Hoses Without Twists or Bends Notice 2. Install the power steering pressure hose (3) to the power steering pump pipe (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the upper air cleaner assembly. 4. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 5. Install the front exhaust pipe, if removed. 6. Install the power steering pressure hose (1) to the power steering gear (3). Tighten Tighten the fitting to 27 N.m (20 lb ft). 7. Lower the vehicle. 8. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 4690 Power Steering Line/Hose: Service and Repair Power Steering - Return Hose POWER STEERING RETURN HOSE REPLACEMENT (WITH RPO CODE 2.2L (L61)) REMOVAL PROCEDURE 1. Remove the upper air cleaner assembly. 2. Remove the clamp (5) and the power steering return hose (2) from the power steering pump (1). 3. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 4. Remove the front exhaust pipe, automatic transmission only. 5. Remove the power steering return hose (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering - Pressure Pipe > Page 4691 1. Install the power steering return hose (2) to the vehicle. NOTE: Refer to Installing Hoses Without Twists or Bends Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Installing Hoses Without Twists or Bends Notice 2. Install the power steering return hose (2) to the power steering gear (3). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the fitting to 27 N.m (20 lb ft). 3. Install the front exhaust pipe, if removed. 4. Lower the vehicle. 5. Install the power steering return hose (2) and the clamp (5) to the power steering pump (1). 6. Install the upper air cleaner assembly. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair Power Steering Pressure Control Valve: Service and Repair POWER STEERING PUMP FLOW CONTROL VALVE REPLACEMENT - OFF VEHICLE DISASSEMBLY PROCEDURE 1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4. Remove the flow control spring (2). ASSEMBLY PROCEDURE 1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the control valve assembly (3). 3. Lubricate the new O-ring seal (4) with power steering fluid. 4. Install the O-ring seal (4) on to the O-ring union fitting (5). 5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the O-ring union fitting to 75 N.m (55 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-02-32-001B > Jul > 04 > Steering - Momentary P/S Reduction On Initial Start Up Power Steering Pump: Customer Interest Steering - Momentary P/S Reduction On Initial Start Up File In Section: 02 - Steering Bulletin No.: 03-02-32-001B Date: July, 2004 TECHNICAL Subject: Momentary Reduction Of Power Steering (P/S) Assist On Initial Start Up With Low Ambient Temperatures (Replace P/S Pump) Models: 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire with 4 Cylinder, 2.2L Gasoline Engine (VIN F - RPO L61) This bulletin is being revised to add the 2005 model year for Chevrolet and Pontiac, add the Classic model and update the Parts Information. Please discard Corporate Bulletin Number 03-02-32-001A (Section 02 - Steering). Condition Some customers may comment on a momentary reduction of power steering (P/S) assist on initial start up with low ambient temperatures about -12°C (10°F). The system returns to full assist after the vehicle has run for a few seconds. Correction Important: DO NOT REPLACE the following steering gears as the steering gear WILL NOT correct this condition: ^ 26073992 ^ 26086616 ^ 26068967 ^ 26068964 ^ 26074935 Replace the P/S pump, P/N 26047567. Refer to Power Steering Pump Replacement, 2.2L (L61) and 2.4L (LD9) (SI Document ID # 790711) and Power Steering Reservoir Replacement - Off Vehicle CB Series (SI Document ID # 482359). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Pump: > 03-02-32-001B > Jul > 04 > Steering - Momentary P/S Reduction On Initial Start Up > Page 4707 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-02-32-001B > Jul > 04 > Steering - Momentary P/S Reduction On Initial Start Up Power Steering Pump: All Technical Service Bulletins Steering - Momentary P/S Reduction On Initial Start Up File In Section: 02 - Steering Bulletin No.: 03-02-32-001B Date: July, 2004 TECHNICAL Subject: Momentary Reduction Of Power Steering (P/S) Assist On Initial Start Up With Low Ambient Temperatures (Replace P/S Pump) Models: 2002-2005 Chevrolet Cavalier 2004-2005 Chevrolet Classic 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire with 4 Cylinder, 2.2L Gasoline Engine (VIN F - RPO L61) This bulletin is being revised to add the 2005 model year for Chevrolet and Pontiac, add the Classic model and update the Parts Information. Please discard Corporate Bulletin Number 03-02-32-001A (Section 02 - Steering). Condition Some customers may comment on a momentary reduction of power steering (P/S) assist on initial start up with low ambient temperatures about -12°C (10°F). The system returns to full assist after the vehicle has run for a few seconds. Correction Important: DO NOT REPLACE the following steering gears as the steering gear WILL NOT correct this condition: ^ 26073992 ^ 26086616 ^ 26068967 ^ 26068964 ^ 26074935 Replace the P/S pump, P/N 26047567. Refer to Power Steering Pump Replacement, 2.2L (L61) and 2.4L (LD9) (SI Document ID # 790711) and Power Steering Reservoir Replacement - Off Vehicle CB Series (SI Document ID # 482359). Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Pump: > 03-02-32-001B > Jul > 04 > Steering - Momentary P/S Reduction On Initial Start Up > Page 4713 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4714 Power Steering Pump Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4715 Power Steering Pump Assembly-CB Series Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Page 4716 Power Steering Pump: Service and Repair POWER STEERING PUMP REPLACEMENT (2.2L (L61)) REMOVAL PROCEDURE 1. Remove the upper air cleaner and duct. 2. Remove the Evaporative Emission Canister Purge Valve if equipped. 3. Remove the power steering hoses from the power steering pump. 4. Remove the power steering pump mounting bolts (2). 5. Remove the power steering pump (1) from the engine. INSTALLATION PROCEDURE 1. Install the power steering pump (1) to the engine. 2. Install the power steering pump mounting bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the power steering pump bolts (2) to 26 N.m (19 lb ft). 3. Install the power steering hoses to the power steering pump (1) 4. Install the Evaporative Emission Canister Purge Valve if equipped. 5. Install the upper air cleaner and duct. 6. Fill the power steering pump with power steering fluid. Refer to Checking and Adding Power Steering Fluid. 7. Bleed the air from the power steering system. Refer to Bleeding the Power Steering System. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4722 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4723 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4724 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4725 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4726 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4727 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4728 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4729 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4730 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4731 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4732 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4733 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4734 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4735 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4736 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4737 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4738 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4739 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4740 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4741 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4742 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4743 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4744 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4745 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4746 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 4747 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Steering Gear Stub Shaft Bearing Kit Steering Gear: Technical Service Bulletins Steering - Steering Gear Stub Shaft Bearing Kit INFORMATION Bulletin No.: 04-02-32-001F Date: December 02, 2009 Subject: Release of Steering Gear Stub Shaft Bearing Kit for Service Models: 2002-2005 Buick Century, LeSabre, Park Avenue, Regal 2002-2007 Buick Rendezvous 2004-2007 Buick Rainier 2005-2007 Buick Buick Allure (Canada), LaCrosse, Terraza 2002-2005 Chevrolet Cavalier, Impala, Malibu Classic, Venture 2002-2007 Chevrolet Monte Carlo 2002-2009 Chevrolet TrailBlazer 2003-2010 Chevrolet Express 2004-2007 Chevrolet Silverado (2WD) (Classic) 1500 Series 2005-2009 Chevrolet Uplander 2002-2009 GMC Envoy Models 2003-2007 GMC Sierra (2WD) (Classic) 1500 Series 2003-2010 GMC Savana 2002-2003 Oldsmobile Bravada 2002-2004 Oldsmobile Alero, Silhouette 2002-2004 Pontiac Aztek 2002-2005 Pontiac Bonneville, Grand Am, Montana, Sunfire 2002-2008 Pontiac Grand Prix (Excluding GTP Models) 2005-2009 Pontiac Montana SV6 2005-2007 Saturn RELAY 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the information. Please discard Corporate Bulletin Number 04-02-32-001E (Section 02 - Steering). GMSPO has released a steering gear stub shaft bearing kit, P/N 26032824, for service on the above-mentioned vehicles. For detailed usage, refer to Group Number 06 (Front Suspension-Steering) of the GM Parts Catalog. Previously, to correct a pinion seal leak or squeak, the steering gear assembly had to be replaced because the pinion stub shaft bearing, seal and seal retainer were not serviceable. Technicians may now order the kit instead of replacing the steering gear assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4752 Steering Gear: Diagrams Rack And Pinion Power Steering Gear Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4753 Rack And Pinion Power Steering Gear Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 4754 Steering Gear: Adjustments RACK AND PINION GEAR RACK BEARING PRELOAD ADJUSTMENT - OFF VEHICLE (RACK AND PINION) 1. Loosen the adjuster plug lock nut (1). 2. Turn the adjuster plug clockwise until the adjuster plug bottoms in the gear assembly. 3. Turn the adjuster plug back 50 degrees to 70 degrees (approximately one flat). 4. Install the adjuster plug lock nut (1) to the adjuster plug. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Hold the adjuster plug stationary while tightening the adjuster plug lock nut (1) to 68 N.m (50 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear Steering Gear: Service and Repair Power Steering Gear Manual Transmission POWER STEERING GEAR REPLACEMENT (MANUAL TRANSMISSION) REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tires and wheels. 3. Remove the power steering hoses from the power steering gear. 4. Remove the tie rod ends from the steering knuckles. 5. Remove the lower pinch bolt from the intermediate shaft. 6. Support the front suspension crossmember (2) with a suitable jack stand. 7. Remove the brake pipes from the retainers on the front suspension support (2). 8. Remove the front suspension crossmember mounting bolts. 9. Lower the front suspension crossmember (2) in order to remove the power steering gear (1). 10. Remove the power steering gear mounting bolts (3). 11. Remove the power steering gear (1) from the front suspension crossmember (2). INSTALLATION PROCEDURE 1. Install the power steering gear (1) to the front suspension crossmember (2). 2. Install the power steering gear mounting bolts (3). Hand tighten the bolts. 3. Raise the front suspension crossmember (2) into position on the vehicle. 4. Install the front suspension crossmember mounting bolts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4757 NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten 1. Tighten the left rear outboard bolt to 110 N.m (71 lb ft). 2. Tighten the right rear outboard bolt to 110 N.m (71 lb ft). 3. Tighten the rear inboard bolts to 110 N.m (71 lb ft). 4. Tighten the power steering gear mounting bolts to 120 N.m (89 lb ft). 5. Install the lower pinch bolt to the intermediate shaft. 6. Install the brake pipes to the retainers on the front suspension crossmember (2). 7. Install the tie rod ends to the steering knuckles. 8. Install the power steering hoses to the power steering gear. 9. Install the tires and wheels. 10. Bleed the power steering system. Refer to Bleeding the Power Steering System. 11. Align the front wheels. Refer to Measuring Wheel Alignment in Wheel Alignment. Automatic Transmission POWER STEERING GEAR REPLACEMENT (AUTOMATIC TRANSMISSION) REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the lower pinch bolt from the intermediate shaft. 3. Remove the front suspension crossmember. 4. Remove the power steering hoses from the power steering gear. 5. Remove the power steering gear mounting bolts (3). 6. Remove the power steering gear (1) from the front suspension crossmember (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4758 1. Install the power steering gear (1) to the front suspension crossmember (2). 2. Install the power steering hoses to the power steering gear. 3. Install the power steering gear mounting bolts (3) NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 120 N.m (89 lb ft). 4. Install the front suspension crossmember. 5. Install the lower pinch bolt to the intermediate shaft. 6. Lower the vehicle. 7. Bleed the power steering system. Refer to Bleeding the Power Steering System. 8. Align the front wheels. Refer to in Measuring Wheel Alignment in Wheel Alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4759 Steering Gear: Service and Repair Rack and Pinion Boot RACK AND PINION BOOT REPLACEMENT - ON VEHICLE TOOLS REQUIRED J 22610 Keystone Clamp Pliers REMOVAL PROCEDURE 1. Remove the outer tie rod. 2. Remove the nut (5) from the inner tie rod assembly. 3. Remove the tie rod clamp (4). 4. Use side cutters to remove the boot clamp (2). 5. Discard the boot clamp. 6. Remove the rack and pinion boot (3). INSTALLATION PROCEDURE 1. Install the new boot clamp (2) onto the rack and pinion boot (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4760 2. Apply grease to the inner rod (2) and apply grease to the gear assembly (1) prior to the boot (3) installation. 3. Install the boot (3) onto the inner tie rod assembly. IMPORTANT:The rack and pinion boot must not be twisted or out of shape in any way. An improperly shaped boot must be shaped by hand before installing the boot clamp. 4. Install the boot (3) onto the gear assembly (1) until the boot is seated in the gear assembly groove. 5. Install the boot clamp on the boot (1) using tool J 22610 (2). 6. Crimp the boot clamp (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4761 7. Install the tie rod end clamp on the boot using pliers. 8. Install the jam nut to the inner tie rod assembly. 9. Install the outer tie rod. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4762 Steering Gear: Service and Repair Rack and Pinion Boot and Breather Tube RACK AND PINION BOOT AND BREATHER TUBE REPLACEMENT - OFF VEHICLE TOOLS REQUIRED J 22610 Service Boot Clamp Installer DISASSEMBLY PROCEDURE 1. To remove the outer tie rod. Refer to Tie Rod End Replacement - Outer. 2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1). 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). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4763 6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion gear assembly. IMPORTANT:If a breather tube is present, mark the location of the breather tube on the gear assembly before removal of the rack and pinion boot. ASSEMBLY PROCEDURE 1. Install the new boot clamp (1) onto the rack and pinion boot (3). 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. If present, install the breather tube while aligning 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 onto the gear assembly (1) until the rack and pinion boot (3) is seated in the gear assembly groove. 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. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4764 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 tie rod end clamp (2) onto the rack and pinion boot (1). 10. Install the hexagon jam nut (2) to the inner tie rod assembly (1). 11. To assemble the outer tie rod assembly. Refer to Tie Rod End Replacement - Outer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4765 Steering Gear: Service and Repair Steering Gear Cylinder Pipe Assemblies/O-Ring Seals STEERING GEAR CYLINDER PIPE ASSEMBLIES/O-RING SEALS REPLACEMENT - OFF VEHICLE (QUIET VALVE) DISASSEMBLY PROCEDURE 1. Loosen both cylinder line fittings on the cylinder end of the gear assembly. 2. Loosen both fittings on the cylinder line assemblies (1) at the valve end of the gear assembly. 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 2. Replace the parts as needed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Power Steering Gear > Page 4766 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). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten - Tighten the valve end fittings to 17 N.m (13 lb ft) - Tighten the cylinder end fittings to 27 N.m (20 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: Customer Interest Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4775 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4776 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4777 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column Steering Shaft: All Technical Service Bulletins Steering - Clunk Felt/Noise Heard From Steering Column Bulletin No.: 07-02-32-006 Date: August 06, 2007 TECHNICAL Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft [I-Shaft]) Models: 1997-2005 Chevrolet Cavalier 1997-2005 Pontiac Sunfire Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel. Cause This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise. Diagnostic Tip This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Engineering investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigation shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction. Correction Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4783 Fully extend the intermediate shaft by pulling the two shafts apart. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4784 Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in. Make sure the intermediate shaft is being pressed over the ears of the solid shaft. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible. Remove the rubber stopper plug from the yoke end of the shaft. Slowly extend the intermediate shaft apart. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-02-32-006 > Aug > 07 > Steering - Clunk Felt/Noise Heard From Steering Column > Page 4785 Before installing the intermediate shaft in the vehicle, make sure to stoke and extend the intermediate shaft at least 15 times to completely lubricate the internal surface of the slip joint. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in Service Information (SI). Parts Information Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4791 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4792 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4802 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Steering Shaft: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4803 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement INTERMEDIATE STEERING SHAFT REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to vehicle Lifting. 2. Remove the left tire and wheel. 3. Reposition the intermediate steering shaft seal in order to gain access to the lower pinch bolt. 4. Remove the lower pinch bolt from the steering gear. 5. Lower the vehicle. 6. Reposition the intermediate steering shaft seal in order to gain access to the upper pinch bolt. 7. Remove the upper pinch bolt from the steering column. 8. Remove the intermediate steering shaft and the intermediate steering shaft seal from the vehicle. INSTALLATION PROCEDURE 1. Install the intermediate steering shaft and the intermediate steering shaft seal to the vehicle. CAUTION: If steering column to cowl panel seal is torn or otherwise damaged, it must be replaced. Confirm that the seal and inner race are properly located. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4810 Failure to do so may allow carbon monoxide into the vehicle, which may result in serious personal injury or death. 2. Install the upper pinch bolt to the steering column. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolt to 40 N.m (30 lb ft). 3. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 4. Install the lower pinch bolt to the steering gear. Tighten Tighten the bolt to 40 N.m (30 lb ft). 5. Install the left tire and wheel. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4811 Steering Shaft: Service and Repair Seal Replacement - Intermediate Steering Shaft SEAL REPLACEMENT - INTERMEDIATE STEERING SHAFT REMOVAL PROCEDURE 1. Remove the intermediate steering shaft. 2. Remove the intermediate steering shaft seal from the front of dash panel. 3. Remove the intermediate steering shaft seal from the vehicle. INSTALLATION PROCEDURE 1. Install the intermediate steering shaft seal to the vehicle. CAUTION: If steering column to cowl panel seal is torn or otherwise damaged, it must be replaced. Confirm that the seal and inner race are properly located. Failure to do so may allow carbon monoxide into the vehicle, which may result in serious personal injury or death. 2. Position the intermediate steering shaft seal on the front of dash panel. 3. Install the intermediate steering shaft. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4812 Steering Shaft: Service and Repair Steering Shaft, Lower Bearing & Jacket Standard Column STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (STANDARD) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Steering Column/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Service Precautions/Technician Safety Information/SIR Caution 2. Remove the steering column jacket. 3. Remove and discard the 4 support screws (1). 4. Remove the support mounting adapter (2). 5. Remove and discard the lower spring retainer (6). 6. Remove the lower bearing spring (5). 7. Remove the lower bearing seat (4). 8. Remove the adapter and bearing assembly (3). 9. Remove and discard the bearing retainer (1). 10. Remove the steering shaft assembly (2) from the steering column jacket. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4813 1. Install the support mounting bracket (2). 2. Lubricate the new support screws (1) with LOCTITE(R) 242, GM P/N 123455382 (Canadian P/N 10953489). 3. Install 4 new support screws (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 8 N.m (71 lb in). 4. Install the steering shaft assembly (2) into the steering column jacket assembly. 5. Install the new bearing retainer (1). IMPORTANT:The bearing retainer must be seated correctly on the steering shaft. 6. Install the adapter and bearing assembly (3). 7. Install the lower bearing seat (4). 8. Install the lower bearing spring (5). IMPORTANT:When installing, compress the lower bearing spring (5) to the length of 23.5 mm (0.93 inches) between the lower bearing seat (4) and the lower spring retainer (6). 9. Install the new lower spring retainer (6). 10. Install the steering column jacket. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Tilt Column STEERING SHAFT, LOWER BEARING, AND JACKET REPLACEMENT (TILT) TOOLS REQUIRED Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4814 J 41688 Centering Sphere Installer REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Steering Column/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Service Precautions/Technician Safety Information/SIR Caution 2. Remove the steering column jacket. 3. Remove the lower spring retainer (5) and discard. 4. Remove the lower bearing spring (4). 5. Remove the lower bearing seat (3). 6. Remove the adapter and bearing assembly (2) from steering column jacket assembly (1). 7. Remove the steering shaft assembly from the steering column jacket assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4815 8. Remove the 4 support screws and discard. 9. Remove the steering column support assembly from the steering column jacket assembly. 10. Tilt the upper shaft assembly (1) 90 degrees to the lower steering shaft assembly (2) and disengage. IMPORTANT:Mark the upper shaft assembly and the lower steering shaft assembly to ensure proper assembly. Failure to assemble properly will cause the steering wheel to be turned 180 degrees. 11. Insert the race and upper shaft assembly (1) into J 41688. 12. Insert J 41688 into a vise. 13. Rotate the driver 90 degrees in the counterclockwise direction in order to disengage the centering sphere from the race and upper shaft assembly. 14. Remove the race and upper shaft assembly (1) from J 41688. 15. Remove the shaft preload spring and the centering sphere from J 41688. 16. If necessary, discard the old centering sphere and the old shaft preload spring. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4816 17. Remove the joint preload spring from the centering sphere. INSTALLATION PROCEDURE 1. Lubricate the centering sphere (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. Install the centering sphere (1) and the joint preload spring (2) into J 41688. 3. Compress the centering sphere and joint preload spring with J 41688. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4817 4. Install the upper shaft assembly. 5. After the race and upper shaft assembly (1) is firmly attached to the centering sphere, rotate the shaft 90 degrees downward in order to lock the centering sphere in place. 6. Remove the centering sphere installer and the race and upper shaft assembly from the vise. 7. Disassemble J 41688 by separating the base. After the tool is disassembled, remove the race and upper shaft from J 41688. 8. Lubricate the centering sphere with GM P/N 12345718 (Canadian P/N 10953516). 9. Using the alignment marks from the disassemble procedure, tilt the upper and lower shafts 90 degrees to each other and engage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4818 10. Install the steering column support assembly to the steering column jacket assembly with the 4 support screws. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 8 N.m (71 lb in). 11. Install the steering shaft assembly into the steering column support assembly. 12. Install the adapter and bearing assembly (2) to the steering column jacket assembly (1). Position the tab on the adapter and bearing assembly with the slot in steering column jacket assembly and push together. 13. Install the lower bearing seat (3). 14. Install the lower bearing spring (4). 15. Install the new lower spring retainer (5). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 4819 When installing, compress the lower bearing spring (4) to the length of 23.5 mm (0.93 in) between the lower bearing seat (3) and the lower spring retainer (5). 16. Install the steering column jacket. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 17. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Description and Operation Steering Wheel: Description and Operation STEERING WHEEL AND COLUMN DESCRIPTION AND OPERATION The steering wheel and column has 4 primary functions: - Vehicle steering - Vehicle security - Driver convenience - Driver safety Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security-Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: - The ignition switch assembly - The steering column lock - The ignition cylinder Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. - The turn signal switch - The hazard switch - The headlamp dimmer switch - The wiper/washer switch - The horn pad/cruise control switch - The redundant radio/entertainment system controls - The tilt or tilt/telescoping functions - The navigation/OnStar(R) features - The HVAC controls Driver Safety The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The mounting capsules break away from the mounting bracket in the event of an accident. The steering wheel and column are designed to absorb energy when driver contact is made with the steering wheel or inflated air bag. In a frontal collision the driver may contact the steering wheel directly or load the steering wheel and column through the inflated air bag. When the driver applies load to the air bag or steering wheel the column will compress downward absorbing some of the impact, helping to reduce bodily injuries to the driver. The steering wheel and column must be inspected for damage after a collision. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement Steering Wheel: Service and Repair Steering Wheel Replacement STEERING WHEEL REPLACEMENT TOOLS REQUIRED - J 1859-A Steering Wheel Puller - J 42578 Steering Wheel Puller Legs REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. CAUTION: Refer to SIR Caution in Service Precautions. See: Service Precautions/Technician Safety Information/SIR Caution 3. Remove the steering wheel inflatable restraint module. 4. Remove the steering wheel nut (1). 5. Remove the steering wheel using J 1859-A and J 42578. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 4825 6. Remove the steering wheel (2) from the steering column (3). INSTALLATION PROCEDURE 1. Install the steering wheel (2) to the column (3). 2. Install the steering wheel nut (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nut to 41 N.m (30 lb ft). 3. Install the inflatable restraint steering wheel module. 4. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 5. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 4826 Steering Wheel: Service and Repair Inflatable Restraint Steering Wheel Module Coil - Centering INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL CENTERING 1. Verify the following conditions before centering the SIR coil: - The wheels on the vehicle are straight ahead. - The block tooth (1) of the steering shaft assembly is in the 12 O'clock position. - The ignition switch assembly is in the LOCK position. NOTE: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 2. If the front (5) of the SIR coil has a centering window (4), and the back side (2) has a spring service lock (1), perform the following steps: 2.1. Hold the coil with the face up. 2.2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops. 2.3. Rotate the coil hub slowly, counterclockwise, until the centering window appears yellow and both arrows (3) line up. 2.4. Release the spring service lock between the locking tab. The SIR coil is now centered. 2.5. Align the centered SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If the front (4) of the SIR coil has a centering window (3) and the back side (1) has NO spring service lock, perform the following steps: 3.1. Hold the coil with the face up. 3.2. Rotate the coil hub clockwise until the coil ribbon stops. 3.3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow and both arrows (2) line up. This is the CENTER Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Steering Wheel Replacement > Page 4827 position. 3.4. While holding the coil hub in the CENTER position, align the coil with the horn tower and slide the coil onto the steering shaft assembly. 4. If no centering window is present on the front side (3) of the SIR coil, but a spring service lock (1) is on the back side (2), perform the following steps: 4.1. Hold the coil with the back side up. 4.2. While depressing the spring service lock, rotate the coil hub in the direction of the arrow (4) until the coil ribbon stops. 4.3. Still pressing the spring service lock, rotate the coil hub in the opposite direction 21/2 revolutions. 4.4. Release the spring service lock between the locking tabs. The SIR coil is now centered. 4.5. Align the centered coil with the horn tower and slide the coil onto the steering shaft assembly. 5. If no centering window appears on the front side (2) of the SIR coil and no spring service lock exists on the back side (1), perform the following steps: 5.1. Hold the coil with the face up. 5.2. Rotate the coil hub in the direction of the arrow until the coil ribbon stops. 5.3. Rotate the coil hub, slowly, counterclockwise, for 21/2 revolutions. This is the CENTER position. 5.4. While maintaining the coil hub in the CENTER position, align the centered coil with the horn tower and slide the coil onto the steering shaft assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering - Snap/Pop Noise When Turning Steering Wheel Tie Rod Boot: Customer Interest Steering - Snap/Pop Noise When Turning Steering Wheel Bulletin No.: 06-02-32-005 Date: May 03, 2006 TECHNICAL Subject: Snap/Pop Type Noise During Steering Wheel Rotation (Replace Inner Tie Rod Boot) Models Condition Some customers may comment about a snap or pop type noise coming from the front of the vehicle. This noise usually occurs during steering wheel rotation. Cause The cause of this condition may be due to the inner tie rod boot collapsing unevenly, allowing for contact between the inner tie rod and the boot. This condition is sometimes referred to as "snaking." Diagnosis If unsure the noise is coming from the inner tie rod boot(s), have an assistant rotate the steering wheel from lock to lock with the engine off. Place your fingertips on the inner tie rod boot. If the boot is contacting the inner tie rod, that contact will be transmitted to your fingertips. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering - Snap/Pop Noise When Turning Steering Wheel > Page 4837 Replace the inner tie rod boot. Refer to the Rack and Pinion Boot Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering Snap/Pop Noise When Turning Steering Wheel Tie Rod Boot: All Technical Service Bulletins Steering - Snap/Pop Noise When Turning Steering Wheel Bulletin No.: 06-02-32-005 Date: May 03, 2006 TECHNICAL Subject: Snap/Pop Type Noise During Steering Wheel Rotation (Replace Inner Tie Rod Boot) Models Condition Some customers may comment about a snap or pop type noise coming from the front of the vehicle. This noise usually occurs during steering wheel rotation. Cause The cause of this condition may be due to the inner tie rod boot collapsing unevenly, allowing for contact between the inner tie rod and the boot. This condition is sometimes referred to as "snaking." Diagnosis If unsure the noise is coming from the inner tie rod boot(s), have an assistant rotate the steering wheel from lock to lock with the engine off. Place your fingertips on the inner tie rod boot. If the boot is contacting the inner tie rod, that contact will be transmitted to your fingertips. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering Snap/Pop Noise When Turning Steering Wheel > Page 4843 Replace the inner tie rod boot. Refer to the Rack and Pinion Boot Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair Tie Rod End: Service and Repair TIE ROD END REPLACEMENT - OUTER TOOLS REQUIRED J 24319-B Universal Steering Linkage Puller REMOVAL PROCEDURE IMPORTANT:Use the J 24319-B in order to separate all the tie rod ends. 1. Remove the front tire and wheel. 2. Remove the nut (5) from the outer tie rod ball stud (4). 3. Loosen the jam nut (2). 4. Use the J 24319-B in order to remove the outer tie rod ball stud from the steering knuckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 4847 5. Remove the tie rod end (4) from the shaft (1). 6. Inspect the inner tie rod shaft (1) for bending or damaged threads. 7. Clean the tapered surface of the steering knuckle (6). INSTALLATION PROCEDURE 1. Install the tie rod end (3) to the inner tie rod shaft (1). 2. Install the outer tie rod ball stud (4) to the steering knuckle (6). 3. Install the new prevailing torque nut (5) to the outer tie rod ball stud (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the new prevailing torque nut to 45 N.m (33 lb ft). 4. Install the front tire and wheel. 5. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment. 6. Tighten the jam nut (2). Tighten Tighten the jam nut to 75 N.m (55 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair Axle Beam: Service and Repair REAR AXLE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assemblies. 3. Remove the brake pipe retainer bolts from the rear axle. 4. Remove the brake pipe from the brake hose and wheel cylinder. 5. Disconnect the wheel speed sensor harness from the wheel speed sensors. 6. Remove the wheel speed sensor wiring harness from the retainers on the rear axle. 7. Disconnect the park brake cables from the equalizers. 8. Remove the park brake cables from the rear axle. 9. Support the rear axle with suitable jack stands. 10. Remove the shock absorber lower mounting bolt (9). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Page 4852 11. Remove the following components from the rear axle (2): - The rear axle mounting bolts (4) - The washers (3) - The nuts (1) 12. Remove the rear axle (2) from the vehicle. INSTALLATION PROCEDURE 1. Install the rear axle (2) to the vehicle. 2. Install the following components to the rear axle (2): - The rear axle mounting bolts (4) - The washers (3) - The nuts (1) 3. Tighten the nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nuts to 120 N.m (89 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Page 4853 4. Install the shock absorber lower mounting bolt (9). Tighten Tighten the bolt to 70 N.m (51 lb ft). 5. Install the park brake cables to the rear axle. 6. Connect the park brake cables to the equalizer. 7. Install the wheel speed sensor wiring harness to the retainers on the rear axle. 8. Connect the wheel speed sensor harness to the wheel speed sensors. 9. Install the brake pipe to the brake hose and wheel cylinder. Tighten Tighten the fittings to 27 N.m (20 lb ft). 10. Install the brake pipe retainer bolts to the rear axle. Tighten Tighten the bolts to 6 N.m (50 lb in). 11. Install the rear tire and wheel assemblies. 12. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Manual)Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes. 13. Adjust the parking brake. Refer to Park Brake Adjustment in Park Brake. 14. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint: Testing and Inspection BALL JOINT INSPECTION TOOLS REQUIRED J 8001 Dial Indicator 1. Raise and support the vehicle with safety stands. Refer to Vehicle Lifting. IMPORTANT:The vehicle must rest on a level surface. The vehicle must be stable. Do not rock the vehicle on the jack stands. 1. Support the lower control arm with a jack stand, as far outboard as possible, near the lower ball joint. 2. Wipe the ball joint clean. Check the seals for cuts or tears. 3. Check the wheel bearings for looseness. If looseness in the wheel bearings is present, refer to Wheel Bearings Diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis IMPORTANT:If a seal is cut or torn, replace the lower ball joint. Refer to Lower Ball Joint Replacement in Front Suspension. 4. Check the ball joint for horizontal looseness. 4.1. Position the J 8001 against the lowest outboard point on the wheel rim. 4.2. Rock the wheel in and out while reading the dial indicator. This shows horizontal looseness in the lower ball joint. 4.3. The dial indicator reading should be no more than 3.18 mm (0.125 in). If the reading is too high, check the lower ball joint for vertical looseness. 5. Check the lower ball joint for wear and for vertical looseness using the following procedure: 5.1. Inspect by sight the lower ball joint for wear. The position of the housing into which the grease fitting is threaded indicates wear. This round Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4857 housing projects 1.27 mm (0.050 in) beyond the surface of the lower ball joint cover on a new ball joint. Under normal wear, the surface of the lower ball joint housing retreats inward very slowly. 5.2. First observe, then scrape a scale, a screwdriver, or a fingernail across the cover. If the round housing is flush with or inside of the cover surface, replace the lower ball joint. Refer to Lower Ball Joint Replacement in Front Suspension. 5.3. Pry between the lower control arm and the steering knuckle while reading the dial indicator. This shows vertical looseness in the ball joint. The lower ball joint is not preloaded and may show some looseness. 5.4. If the dial indicator reading is more than 3.18 mm (0.125 in), replace the lower control arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4858 Ball Joint: Service and Repair LOWER BALL JOINT REPLACEMENT TOOLS REQUIRED J 43828 Ball Joint Separator REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. If the vehicle is equipped with a stabilizer shaft, remove the stabilizer shaft link. 4. Remove the wiring harness from the lower control arm. 5. Remove the cotter pin (1) from the ball joint (3). 6. Remove the nut (4) from the ball joint (3). 7. Separate the ball joint stud from the steering knuckle using the J 43828. NOTE: Use only the recommended tools for separating the ball joint from the knuckle. Failure to use the recommended tools may cause damage to the ball joint and seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4859 8. Remove the lower control arm front (5) and rear (4) mounting bolts. 9. Remove the lower control arm (2) from the vehicle and place in a vice. 10. Drill out the 3 rivets (3) retaining the ball joint to the lower control arm (2). Use a 3 mm (1/8 in) drill bit in order to make a pilot hole through the rivets. Finish drilling the rivets with a 13 mm (1/2 in) drill bit. 11. Remove the ball joint (4) from the control arm (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4860 1. Install the ball joint (4) into the control arm (2). 2. Install the 3 ball joint bolts (3) and the nuts (1). Follow the instructions in the ball joint kit. Tighten the ball joint bolts (3) according to the specifications in the instructions. 3. Install the lower control arm (2) to the front suspension support (1) 4. Install the lower control arm front (5) and rear (4) mounting bolts. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the front bolt to 107 N.m (79 lb ft). - Tighten the rear bolt to 170 N.m (125 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 4861 1. Install the lower ball joint stud (3) to the steering knuckle (2). 2. Install the ball joint stud (3) through the steering knuckle (2). 3. Install the ball joint nut (4). Tighten Tighten the ball joint nut to 55 N.m (41 lb ft) plus 180 degrees rotation minimum-65 N.m (50 lb ft) maximum plus 180 degrees rotation to install the cotter pin. 4. Install the wiring harness to the lower control arm. 5. Install the cotter pin (1). 6. If the vehicle is equipped with a stabilizer shaft, remove the stabilizer shaft link. Refer to Stabilizer Shaft Replacement. 7. Install the tire and wheel assemblies. 8. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension Control Arm Bushing: Service and Repair Front Suspension LOWER CONTROL ARM BUSHINGS REPLACEMENT TOOLS REQUIRED - J 21474-4 1/2 inch Nut - J 21474-18 3/8 inch Nut - J 21474-19 3/8 inch Bolt - J 23444-A High Pressure Lubricant - J 41211 Lower Front Control Arm Vertical Bushing Set - J 41397 Lower Control Arm Bushings Remover/Installer REMOVAL PROCEDURE 1. Remove the lower control arm. 2. Secure the lower control arm in a vice. 3. Assemble the following bushing removal tools as shown: - J 21474-19 - The remover/installer from the J 41397 - The receiver from the J 41397 - J 21474-18 IMPORTANT:Apply J 23444 A or equivalent high pressure lubricant to the threads of the J 21474-19 4. Tighten the J 21474-18 until the front bushing is removed from the control arm. 5. Disassemble the bushing removal tools. 6. Assemble the following bushing removal tools as shown: - J 21474-27 - The remover/installer from the J 41211 - The receiver from the J 41211 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 4867 - J 21474-4 7. Tighten the J 21474-27 until the rear bushing is removed from the control arm. 8. Disassemble the bushing removal tools. INSTALLATION PROCEDURE 1. Insert the rear bushing into the control arm. 2. Assemble the following bushing installation tools as shown: - J 21474-27 - The receiver/installer from the J 41211 - The receiver from the J 41211 - J 21474-4 IMPORTANT:Apply J 23444 A or equivalent high pressure lubricant to the threads of the J 21474-27. 3. Tighten the J 21474-4 until the rear bushing is fully seated in the control arm. 4. Disassemble the bushing installation tools. 5. Lubricate the outer casing of the front bushing. 6. Insert the front bushing into the control arm. 7. Assemble the following bushing installation tools as shown: - J 21474-19 - The remover/installer from the J 41397 - The receiver from the J 41397 - J 21474-18 8. Tighten the J 21474-19 until the front bushing is fully seated in the control arm. 9. Disassemble the bushing installation tools. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 4868 10. Install the lower control arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 4869 Control Arm Bushing: Service and Repair Rear Suspension CONTROL ARM BUSHING REPLACEMENT TOOLS REQUIRED - J 21474-18 3/8 Inch Nut - J 21474-19 3/8 Inch Bolt - J 29376-A Rear Control Arm Bushing Service Set - J 29376-95 Rear Control Arm Bushing Adapter REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Disconnect the brake hoses from the axle. 4. Remove the wheel speed sensor harness from the retainers on the axle. 5. Remove the following components from the control arm: - The bolts - The washers - The nuts 6. Rotate the control arm downward in order to gain access to the bushings. 7. Install the J 29376-95 on the rear control arm. 8. Install the coupling from the J 29376-A to the J 29376-95 on the rear control arm. 9. Assemble the following bushing removal tools as shown: 9.1. J 21474-19 9.2. The remover from the J 29376-A 9.3. The pressure plate from the J 29376-A Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Suspension > Page 4870 9.4. J 21474-18 10. Tighten the J 21474-19 until the bushing is removed from the control arm. 11. Disassemble the bushing removal tools. INSTALLATION PROCEDURE 1. Coat the outside case of the bushing with a light coat of grease prior to installation. 2. Insert the bushing into the control arm. 3. Assemble the following bushing installation tools as shown: 3.1. J 21474-19 3.2. The pressure plate from the J 29376-A 3.3. The installer from the J 29376-A 3.4. J 21474-18 4. Tighten the J 21474-19 until the bushing is completely seated in the control arm. 5. Disassemble the bushing installation tools. 6. Install the following components: - The bolts - The nuts - The washers 7. Hand tighten the nuts. 8. Install the wheel speed sensor harness to the rear axle. 9. Connect the brake hoses to the rear axle. 10. Install the tire and wheel assemblies. 11. Lower the vehicle. 12. Tighten the control arm nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the control arm nuts to 120 N.m (52 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement Cross-Member: Service and Repair Cross Vehicle Brace Replacement Cross Vehicle Brace Replacement Removal Procedure 1. Remove the right front fender liner. 2. Remove the wiring harness retainers. 3. Remove the front suspension support brace. 4. Remove the lower brace bolts (2). 5. Remove the lower brace (1) from the vehicle. Installation Procedure 1. Install the lower brace (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower brace bolts (2). Tighten the lower brace bolts to 25 N.m (18 lb ft). 3. Install the front suspension support brace. 4. Install the wiring harness retainers. 5. Install the right front fender liner. Front Fender Liner Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement > Page 4875 Cross-Member: Service and Repair Frame and Underbody Crossmember Replacement Removal Procedure 1. Raise and support the vehicle.Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the front fender liners. 4. Remove the engine strut from the lower engine mount and frame. 5. Remove the front exhaust pipe. 6. Disconnect the ABS harness from the lower control arms. 7. Disconnect the ball joints from the steering knuckles. 8. Disconnect the tie rods from the steering knuckles. 9. On vehicles with a brake pipe running along the crossmember, disconnect the brake pipe from the retainers. 10. Remove the power steering gear to crossmember mounting bolts. 11. Secure the power steering gear to the body, taking care not to over extend the intermediate shaft. 12. Remove the front suspension support brace. 13. Support the crossmember, using suitable jack stands. 14. Remove the front suspension crossmember mounting bolts. 15. Lower the crossmember from the vehicle. 16. If replacing the crossmember, remove the following components: * The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement. Installation Procedure 1. If replacing the crossmember, Install the following components: * The stabilizer shaft. Refer to Stabilizer Shaft Replacement. * The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. 2. Using suitable jack stands, raise the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement > Page 4876 3. Install the front suspension crossmember mounting bolts. 1. Tighten the left rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees. 2. Tighten the right rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees. 3. Tighten the front upper bolts to 110 N.m (81 lb ft) plus an additional 90 degrees. 4. Tighten the rear inboard bolts to 110 N.m (81 lb ft) plus an additional 90 degrees. 4. Install the front suspension support brace. 5. Reposition the steering gear to the crossmember. 6. Install the power steering gear to crossmember mounting bolts. Tighten the bolts to 120 N.m (89 lb ft). 7. On vehicles with the brake pipe running along the support frame, install the brake pipe into the retainers. 8. Connect the tie rods to the steering knuckle. 9. Connect the lower control arms to the steering knuckles. 10. Connect the ABS harness to the lower control arms. 11. Install the front exhaust pipe. 12. Install the engine strut to the lower engine mount and frame. 13. Install the front fender liners. 14. Install the tire and wheel assemblies. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair STEERING KNUCKLE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the tie rod from the steering knuckle. 4. If the vehicle is equipped with ABS, disconnect the ABS electrical connector. 5. Remove the hub and bearing assembly. 6. Remove the bolts (3) and nuts (6) that attach the steering knuckle (4) to the strut (2). 7. Remove the lower ball joint from the steering knuckle. 8. Remove the steering knuckle (4) from the vehicle. INSTALLATION PROCEDURE 1. Install the steering knuckle (4) to the vehicle. 2. Install the lower ball joint to the steering knuckle. 3. Install the bolts (3) and the nuts (6) attaching the steering knuckle (4) to the strut (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nuts (6) to 180 N.m (133 lb ft). 4. Install the hub and bearing assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Page 4880 5. If the vehicle is equipped with ABS, connect the ABS electrical connector. 6. Install the tie rod to the steering knuckle. 7. Install the tire and wheel assemblies. 8. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning Stabilizer Bushing: Customer Interest Suspension - Popping/Rattling Noise When Turning Bulletin No.: 02-03-08-008B Date: August 18, 2006 TECHNICAL Subject: Rattle/Creak/Popping Type Noise from Front of Vehicle When Turning (Replace Both Front Stabilizer Shaft Insulator Brackets) Models: 2002-2005 Chevrolet Cavalier 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire with FE1, FE2 or FE3 Suspension Supercede: This bulletin is being revised to include FE3 suspension. Please discard Corporate Bulletin Number 02-03-08-008A (Section 03 - Suspension). Condition Some customers may comment on a rattle/creak/popping type noise coming from the front of the vehicle when turning the steering wheel. This noise can typically be duplicated with a short drive on uneven road surfaces, then turning the vehicle left or right into a 90 degree turn. Cause This condition may be caused by the front stabilizer shaft insulator to front suspension crossmember brackets being out of specification. Using the J 39570 Chassis Ear hooked up to each bracket may assist in determining if they are the source of the noise. Correction Replace both the front stabilizer shaft insulator brackets using the procedure listed below. Raise and suitably support the vehicle. Remove the front tire and wheel assemblies. Reposition the intermediate steering shaft seal in order to gain access to the lower pinch bolt. Remove the lower pinch bolt from the steering gear. Support the front suspension crossmember with a suitable jackstand. Remove the rear mounting bolts from the front suspension crossmember. Remove the center mounting bolts from the front suspension crossmember. Remove the front mounting bolts from the front suspension crossmember. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning > Page 4890 Lower the front suspension crossmember approximately 15 cm (6 in) by adjusting the jackstand down. Remove the retaining bolts and stabilizer shaft insulator brackets. Install the new stabilizer shaft insulator brackets and retaining bolts. Tighten Tighten the stabilizer shaft insulator bracket bolts to 66 N.m (49 lb ft). Install the front mounting bolts to the front suspension crossmember. Hand tighten the bolts. Install the center mounting bolts to the front suspension crossmember. Hand tighten the bolts. Install the rear mounting bolts to the front suspension crossmember. Hand tighten the bolts. Tighten Tighten the left rear bolt to 110 N.m (71 lb-ft). Tighten the right rear bolt to 110 N.m (71 lb-ft). Tighten the left front bolt to 110 N.m (71 lb-ft). Tighten the right front bolt to 110 N.m (71 lb-ft). Tighten the center bolts to 110 N.m (71 lb-ft). Tighten the stabilizer shaft insulator brackets bolts to 66 N.m (49 lb ft). Install the lower pinch bolt from the steering gear. Tighten Tighten the bolt to 40 N.m (30 lb ft). Install the front tire and wheel assemblies. Tighten Tighten the nuts in a criss-cross pattern 140 N.m (100 lb ft). Lower the vehicle. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning > Page 4891 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning Stabilizer Bushing: All Technical Service Bulletins Suspension - Popping/Rattling Noise When Turning Bulletin No.: 02-03-08-008B Date: August 18, 2006 TECHNICAL Subject: Rattle/Creak/Popping Type Noise from Front of Vehicle When Turning (Replace Both Front Stabilizer Shaft Insulator Brackets) Models: 2002-2005 Chevrolet Cavalier 2002-2004 Oldsmobile Alero 2002-2005 Pontiac Grand Am, Sunfire with FE1, FE2 or FE3 Suspension Supercede: This bulletin is being revised to include FE3 suspension. Please discard Corporate Bulletin Number 02-03-08-008A (Section 03 - Suspension). Condition Some customers may comment on a rattle/creak/popping type noise coming from the front of the vehicle when turning the steering wheel. This noise can typically be duplicated with a short drive on uneven road surfaces, then turning the vehicle left or right into a 90 degree turn. Cause This condition may be caused by the front stabilizer shaft insulator to front suspension crossmember brackets being out of specification. Using the J 39570 Chassis Ear hooked up to each bracket may assist in determining if they are the source of the noise. Correction Replace both the front stabilizer shaft insulator brackets using the procedure listed below. Raise and suitably support the vehicle. Remove the front tire and wheel assemblies. Reposition the intermediate steering shaft seal in order to gain access to the lower pinch bolt. Remove the lower pinch bolt from the steering gear. Support the front suspension crossmember with a suitable jackstand. Remove the rear mounting bolts from the front suspension crossmember. Remove the center mounting bolts from the front suspension crossmember. Remove the front mounting bolts from the front suspension crossmember. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning > Page 4897 Lower the front suspension crossmember approximately 15 cm (6 in) by adjusting the jackstand down. Remove the retaining bolts and stabilizer shaft insulator brackets. Install the new stabilizer shaft insulator brackets and retaining bolts. Tighten Tighten the stabilizer shaft insulator bracket bolts to 66 N.m (49 lb ft). Install the front mounting bolts to the front suspension crossmember. Hand tighten the bolts. Install the center mounting bolts to the front suspension crossmember. Hand tighten the bolts. Install the rear mounting bolts to the front suspension crossmember. Hand tighten the bolts. Tighten Tighten the left rear bolt to 110 N.m (71 lb-ft). Tighten the right rear bolt to 110 N.m (71 lb-ft). Tighten the left front bolt to 110 N.m (71 lb-ft). Tighten the right front bolt to 110 N.m (71 lb-ft). Tighten the center bolts to 110 N.m (71 lb-ft). Tighten the stabilizer shaft insulator brackets bolts to 66 N.m (49 lb ft). Install the lower pinch bolt from the steering gear. Tighten Tighten the bolt to 40 N.m (30 lb ft). Install the front tire and wheel assemblies. Tighten Tighten the nuts in a criss-cross pattern 140 N.m (100 lb ft). Lower the vehicle. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 02-03-08-008B > Aug > 06 > Suspension - Popping/Rattling Noise When Turning > Page 4898 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Page 4899 Stabilizer Bushing: Service and Repair STABILIZER SHAFT INSULATOR REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assemblies. 3. Remove the stabilizer shaft from the vehicle. 4. Remove the stabilizer shaft bushings (5) from the stabilizer shaft (3). INSTALLATION PROCEDURE 1. Install the stabilizer shaft bushings (5) to the stabilizer shaft (3). 2. Install the stabilizer shaft to the vehicle. 3. Install the tire and wheel assemblies. 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair Stabilizer Link: Service and Repair STABILIZER SHAFT LINK REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the stabilizer link nut (3) from the stabilizer link bolt (6). 3. Remove the following components: - The stabilizer link bolt (6) - The insulator (5) - The spacer (4) INSTALLATION PROCEDURE 1. Install the following components: - The spacer (4) - The insulator (5) - The stabilizer (6) 2. Install the stabilizer link nut (3) attaching the stabilizer link to the stabilizer link bolt (6). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nut until the nut meets the end of the bolt threads for torque value. Tighten the nut to 17 N.m (13 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Page 4903 3. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair FRONT SUSPENSION SUPPORT BRACE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the bolt (2) from the front suspension support brace (3) and the front suspension crossmember (1). 3. Remove the bolt (4) from the front suspension support brace (3) and the lower tie bar (5). 4. Remove the front suspension support brace (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the front suspension support brace (3) to the vehicle. 2. Install the bolt (4) to the suspension support brace (3) and lower the tie bar (5). Hand tighten the bolt. 3. Install the bolt (4) to the front suspension support brace (3) and the front suspension crossmember (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 72 N.m (53 lb ft). 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > System Diagnosis Front Subframe: Testing and Inspection Checking Frame Alignment The main components of the frame are the side rails and the crossmembers. The rails carry the load. The crossmembers stabilize the rails. The 5 types of frame misalignment are the following: * Sag * Buckle * Diamond * Sidesway * Twist A misaligned frame rail may move in the following directions from where the frame rail should be: * Forward * Up * Down * To the side The easiest way to inspect the frame alignment is with gauges that are made for this purpose. Detailed instructions are normally supplied with the gauges at the time of purchase. There are no instructions for gauge use in the manual. Whether you inspect the alignment with or without gauges, park the vehicle on a level section of floor. Certain conditions call for preliminary inspections before inspecting the frame. Suspension or axle problems may make it appear that the vehicle frame is out of alignment. If an axle has shifted, diamond or sidesway may appear to exist when neither do exist. A weak spring may make the vehicle appear to have a twisted frame. A visual inspection of the top and the bottom flanges of each rail may reveal the specific area where the sag or the buckle exist. In the case of a sag, wrinkles may appear on the top of the upper flange. The wrinkles are definite evidence of sag. Wrinkles on the bottom of the lower flange are definite evidence of buckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-015B > May > 05 > Suspension - Front End Squeaking Noise When Turning Suspension Strut / Shock Absorber: Customer Interest Suspension - Front End Squeaking Noise When Turning Bulletin No.: 04-03-08-015B Date: May 09, 2005 TECHNICAL Subject: Squeak Noise In Front End On Turns (Replace Strut Spring Seat) Models: 1999-2004 Chevrolet Cavalier 2000-2003 Chevrolet Malibu 2004-2005 Chevrolet Classic 2000-2004 Oldsmobile Alero 2000-2005 Pontiac Grand Am 1999-2004 Pontiac Sunfire Attention: Before performing the procedure in this bulletin, technicians should refer to Corporate Bulletin Number 02-03-08-008A if the vehicle has a rattle/creak or popping noise in the front end. Supercede: This bulletin is being revised to add the above Attention statement referencing Corporate Bulletin Number 02-03-08-008A. Please discard Corporate Bulletin Number 04-03-08-015A (Section 03 Suspension). Condition Some customers may comment that the front end of the vehicle has a squeaking noise on left or right turns. Cause This condition may be caused by metal to metal contact between the strut mount and the spring seat. Correction Replace the strut spring seat, P/N 89047655. This new seat includes a deflector ring and will eliminate the contact between the strut mount and the spring seat. Refer to Strut, Strut Component And Or Spring Replacement. The documents below are for Chevrolet Cavalier and Pontiac Sunfire. ^ 1999 Document ID #173282. ^ 2000 Document ID #529476. ^ 2001 Document ID #635853. ^ 2002-2003 Document ID #630647. ^ 2004 Document ID #1173083. The document below is for the Chevrolet Classic. ^ 2004-2005 Document ID #1174192 The documents below are for the Chevrolet Malibu. ^ 2000 Document ID #528929. ^ 2001-2005 Document ID #640868. The documents below are for the Oldsmobile Alero and Pontiac Grand Am. ^ 2000 Document ID #526124. ^ 2001-2003 Document ID #635853. ^ 2004 Document ID #1173889. ^ 2005 (Grand Am only) Document ID #1173889. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest: > 04-03-08-015B > May > 05 > Suspension - Front End Squeaking Noise When Turning > Page 4919 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 4925 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 04-03-08-015B > May > 05 > Suspension - Front End Squeaking Noise When Turning Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front End Squeaking Noise When Turning Bulletin No.: 04-03-08-015B Date: May 09, 2005 TECHNICAL Subject: Squeak Noise In Front End On Turns (Replace Strut Spring Seat) Models: 1999-2004 Chevrolet Cavalier 2000-2003 Chevrolet Malibu 2004-2005 Chevrolet Classic 2000-2004 Oldsmobile Alero 2000-2005 Pontiac Grand Am 1999-2004 Pontiac Sunfire Attention: Before performing the procedure in this bulletin, technicians should refer to Corporate Bulletin Number 02-03-08-008A if the vehicle has a rattle/creak or popping noise in the front end. Supercede: This bulletin is being revised to add the above Attention statement referencing Corporate Bulletin Number 02-03-08-008A. Please discard Corporate Bulletin Number 04-03-08-015A (Section 03 Suspension). Condition Some customers may comment that the front end of the vehicle has a squeaking noise on left or right turns. Cause This condition may be caused by metal to metal contact between the strut mount and the spring seat. Correction Replace the strut spring seat, P/N 89047655. This new seat includes a deflector ring and will eliminate the contact between the strut mount and the spring seat. Refer to Strut, Strut Component And Or Spring Replacement. The documents below are for Chevrolet Cavalier and Pontiac Sunfire. ^ 1999 Document ID #173282. ^ 2000 Document ID #529476. ^ 2001 Document ID #635853. ^ 2002-2003 Document ID #630647. ^ 2004 Document ID #1173083. The document below is for the Chevrolet Classic. ^ 2004-2005 Document ID #1174192 The documents below are for the Chevrolet Malibu. ^ 2000 Document ID #528929. ^ 2001-2005 Document ID #640868. The documents below are for the Oldsmobile Alero and Pontiac Grand Am. ^ 2000 Document ID #526124. ^ 2001-2003 Document ID #635853. ^ 2004 Document ID #1173889. ^ 2005 (Grand Am only) Document ID #1173889. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 04-03-08-015B > May > 05 > Suspension - Front End Squeaking Noise When Turning > Page 4930 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Other Service Bulletins for Suspension Strut / Shock Absorber: > 05-03-08-002C > Oct > 09 > Suspension - Shock Absorber/Strut Leakage Information > Page 4936 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement Suspension Strut / Shock Absorber: Service and Repair Shock Absorber - Replacement SHOCK ABSORBER REPLACEMENT REMOVAL PROCEDURE 1. Reposition the rear compartment carpet to allow access to the shock absorber upper mounting nut (1). 2. Remove the shock absorber upper mounting nut (1). 3. Raise the vehicle on a hoist. 4. Remove the tire and wheel. 5. Place a jackstand under the rear axle in order to maintain tension on the shock absorber (5). 6. Remove the shock absorber upper mounting bolts (2). 7. Lower the jackstand in order to relieve tension on the shock absorber (5). 8. Remove the shock absorber lower mounting bolt (4). 9. Remove the shock absorber (5) from the vehicle. INSTALLATION PROCEDURE 1. Install the shock absorber (5) to the vehicle. 2. Install the shock absorber lower mounting bolt (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4939 Tighten the bolt to 70 N.m (51 lb ft). 3. Raise the rear axle with a jackstand until the shock absorber (5) is in position to install the upper mounting bolts (2). 4. Install the shock absorber upper mounting bolts (2). Tighten Tighten the bolts to 25 N.m (18 lb ft). 5. Remove the jackstand and lower the vehicle. 6. Install the shock absorber upper mounting nut (1). Tighten Tighten the nut to 25 N.m (18 lb ft). 7. Install the tire and wheel. 8. Replace the rear compartment carpet to the original position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4940 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber - Disposal SHOCK ABSORBER DISPOSAL CAUTION: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the center punch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4941 Suspension Strut / Shock Absorber: Service and Repair Strut - Disassemble, Assemble, Repair STRUT DISASSEMBLE/ASSEMBLE REPAIR TOOLS REQUIRED - J 34013-B Strut Spring Compressor - J 3289-20 Holding Fixture Bench Mount - J 34013-88 Compressor Adapter REMOVAL PROCEDURE 1. Remove the strut assembly. Refer to Strut Assembly Replacement. 2. Mount the J 34013-B into the J 3289-20. 3. Install the strut assembly into the J 34013-B using the J 34013-88. 4. Compress the coil spring. 5. Remove the dust cap (1). 6. Remove the strut rod piston nut (2). 7. Release the compressed spring (10). 8. Remove the strut assembly from the J 34013-B. 9. Remove the following components from the strut: - The strut support (3) - The dust seal (4) - The spring seat (5) - The upper insulator (6) - The coil spring (10) - The spring bumper (7) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4942 - The lower insulator (9) INSTALLATION PROCEDURE 1. Install the following components to the strut: - The lower insulator (9) - The spring bumper (7) - The coil spring (10) - The upper insulator (6) - The spring seat (5) - The dust seal (4) - The strut support (3) 2. Mount the strut assembly into the J 34013-B using the J 34013-88. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4943 3. Compress the coil spring (10). 4. Install the strut rod piston nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the strut rod piston nut (2) to 47 N.m (34 lb ft). 5. Pack the strut support with the wheel bearing lubricant GM P/N 1051344 (Canadian P/N 933037), or equivalent. 6. Install the dust cap (1). 7. Release the compressed coil spring (10). 8. Remove the strut from the J 34013-B. 9. Install the strut assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4944 Suspension Strut / Shock Absorber: Service and Repair Strut and Knuckle - Scribing STRUT AND KNUCKLE SCRIBING 1. Scribe the knuckle along the lower outboard strut radius shown by the dotted line (1). Use a sharp tool. 2. Scribe the strut flange on the inboard side along the curve of the knuckle shown by the dotted line (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4945 3. Make a scribe mark across the strut/knuckle interface (3). 4. Match the marks to the components during reassembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4946 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber - Replacement SHOCK ABSORBER REPLACEMENT REMOVAL PROCEDURE 1. Reposition the rear compartment carpet to allow access to the shock absorber upper mounting nut (1). 2. Remove the shock absorber upper mounting nut (1). 3. Raise the vehicle on a hoist. 4. Remove the tire and wheel. 5. Place a jackstand under the rear axle in order to maintain tension on the shock absorber (5). 6. Remove the shock absorber upper mounting bolts (2). 7. Lower the jackstand in order to relieve tension on the shock absorber (5). 8. Remove the shock absorber lower mounting bolt (4). 9. Remove the shock absorber (5) from the vehicle. INSTALLATION PROCEDURE 1. Install the shock absorber (5) to the vehicle. 2. Install the shock absorber lower mounting bolt (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4947 Tighten Tighten the bolt to 70 N.m (51 lb ft). 3. Raise the rear axle with a jackstand until the shock absorber (5) is in position to install the upper mounting bolts (2). 4. Install the shock absorber upper mounting bolts (2). Tighten Tighten the bolts to 25 N.m (18 lb ft). 5. Remove the jackstand and lower the vehicle. 6. Install the shock absorber upper mounting nut (1). Tighten Tighten the nut to 25 N.m (18 lb ft). 7. Install the tire and wheel. 8. Replace the rear compartment carpet to the original position. Shock Absorber - Disposal SHOCK ABSORBER DISPOSAL CAUTION: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. To prevent personal injury, wear safety glasses when center punching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the center punch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Strut - Disassemble, Assemble, Repair STRUT DISASSEMBLE/ASSEMBLE REPAIR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4948 TOOLS REQUIRED - J 34013-B Strut Spring Compressor - J 3289-20 Holding Fixture Bench Mount - J 34013-88 Compressor Adapter REMOVAL PROCEDURE 1. Remove the strut assembly. Refer to Strut Assembly Replacement. 2. Mount the J 34013-B into the J 3289-20. 3. Install the strut assembly into the J 34013-B using the J 34013-88. 4. Compress the coil spring. 5. Remove the dust cap (1). 6. Remove the strut rod piston nut (2). 7. Release the compressed spring (10). 8. Remove the strut assembly from the J 34013-B. 9. Remove the following components from the strut: - The strut support (3) - The dust seal (4) - The spring seat (5) - The upper insulator (6) - The coil spring (10) - The spring bumper (7) - The lower insulator (9) INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4949 1. Install the following components to the strut: - The lower insulator (9) - The spring bumper (7) - The coil spring (10) - The upper insulator (6) - The spring seat (5) - The dust seal (4) - The strut support (3) 2. Mount the strut assembly into the J 34013-B using the J 34013-88. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4950 3. Compress the coil spring (10). 4. Install the strut rod piston nut. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the strut rod piston nut (2) to 47 N.m (34 lb ft). 5. Pack the strut support with the wheel bearing lubricant GM P/N 1051344 (Canadian P/N 933037), or equivalent. 6. Install the dust cap (1). 7. Release the compressed coil spring (10). 8. Remove the strut from the J 34013-B. 9. Install the strut assembly. Strut and Knuckle - Scribing STRUT AND KNUCKLE SCRIBING Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4951 1. Scribe the knuckle along the lower outboard strut radius shown by the dotted line (1). Use a sharp tool. 2. Scribe the strut flange on the inboard side along the curve of the knuckle shown by the dotted line (2). 3. Make a scribe mark across the strut/knuckle interface (3). 4. Match the marks to the components during reassembly. Strut and/or Spring - Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4952 STRUT, STRUT COMPONENT AND/OR SPRING REPLACEMENT TOOLS REQUIRED - J 34013-B Strut Compressor - J 3289-20 Holding Fixture - J 34013-88 Strut Compressor Adapter REMOVAL PROCEDURE 1. Remove the strut assembly. 2. Mount the J 34013-B into the J 3289-20. 3. Install the strut assembly into the J 34013-B using the J 34013-88. 4. Compress the coil spring. 5. Remove the dust cap (1). 6. Remove the strut rod piston nut (2). 7. Release the compressed spring (10). 8. Remove the strut assembly from the J 34013-B 9. Remove the following components from the strut: 9.1. The strut support (3) 9.2. The dust seal (4) 9.3. The spring seat (5) 9.4. The upper insulator (6) 9.5. The coil spring (10) 9.6. The spring bumper (7) 9.7. The lower insulator (9) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4953 INSTALLATION PROCEDURE 1. Install the following components to the strut: 1.1. The lower insulator (9) 1.2. The spring bumper (7) 1.3. The coil spring (10) 1.4. The upper insulator (6) 1.5. The spring seat (5) 1.6. The dust seal (4) 1.7. The strut support (3) 2. Mount the strut assembly into the J 34013-B using the J 34013-88. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4954 3. Compress the coil spring (10). 4. Install the strut rod piston nut and hold the strut rod, at the top, from turning. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the strut rod piston nut (2) to 75 N.m (55 lb ft). 5. Install the dust cap (1). 6. Release the compressed coil spring (10). 7. Remove the strut from the J 34013-B. 8. Install the strut assembly. Front Suspension STRUT ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Refer to Suspension Spring Handling Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4955 1. Remove the nuts (1) and the bolt (2) attaching the top of the strut assembly (5) to the body (3). 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Place jackstands under the the lower control arm. 4. Lower the vehicle slightly so that the weight of the vehicle rests on the jack stand and on the lower control arms. 5. Remove the tire and wheel assembly. 6. Scribe the strut flange. Refer to Strut and Knuckle Scribing. 7. Remove the bolts (3) and the nuts (6) that attach the strut (2) to the steering knuckle (4). 8. Remove the strut assembly (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4956 1. Install the strut assembly (2) to the vehicle. 2. Install the bolts (3) and the nuts (6) attaching the strut (2) to the steering knuckle (4). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 180 N.m (133 lb ft). 3. Lower the vehicle. 4. Install the nuts (1) and the bolt (2) that attach the top of the strut assembly (5) to the body (3). Tighten Tighten the nuts and the bolt to 25 N.m (18 lb ft). 5. Install the tire and wheel assembly. 6. Inspect the front wheel alignment. Rear Suspension STRUT ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Scribe the strut to the knuckle. Refer to Strut and Knuckle Scribing in Front Suspension. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4957 4. Remove the strut mount to body nut (1) in the trunk area. 5. Remove the strut bolts (3) from inside the fender well. 6. Remove the strut knuckle bolts (5) and nuts (3) from the strut (1). 7. Remove the strut (1) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4958 1. Loosely install the strut to knuckle bolts (5) and nuts (3). 2. Install the strut to body bolts (3) inside the fender well. IMPORTANT:Align the scribe marks in order to ensure proper alignment. 3. Install the strut mount to body nuts (1) in the trunk area. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the nuts to 25 N.m (18 lb ft). - Tighten the strut to knuckle bolts to 120 N.m (89 lb ft). 1. Install the tire and wheel assembly. 2. Lower the vehicle. 3. Check the wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment. Suspension Strut - Disposal SUSPENSION STRUT DISPOSAL CAUTION: Use the proper eye protection when drilling to prevent metal chips from causing physical injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber - Replacement > Page 4959 1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil. 3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down. 5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection WHEEL BEARINGS DIAGNOSIS TOOLS REQUIRED J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Hub/Axle Flange and Wheel Stud Runout Inspection in Vibration Diagnosis and Correction. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. IMPORTANT:If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 in), replace the wheel bearing/hub. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension WHEEL BEARING/HUB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the drive axle nut. 4. Remove the brake rotor 5. Remove the mounting bolts (1) from the hub and bearing assembly (3). 6. Remove the hub and bearing assembly (1) from the steering knuckle (2) and drive axle shaft. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4965 1. Install the hub and bearing assembly (1) into the steering knuckle (2) and drive axle shaft. 2. Install the hub bearing mounting bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 95 N.m (70 lb ft). 3. Install the drive axle shaft nut. Tighten Tighten the drive axle shaft nut to 200 N.m (148 lb ft). 4. Install the brake rotor. 5. Install the tire and wheel assemblies. 6. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 4966 Wheel Bearing: Service and Repair Rear Suspension WHEEL BEARING/HUB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake drum. NOTE: Do not hammer on brake drum as damage to the bearing could result. 4. Disconnect the rear ABS wheel speed sensor wire connector. 5. Remove the hub and bearing assembly bolts 6. Remove the hub and bearing assembly from the axle. INSTALLATION PROCEDURE 1. Install the hub and bearing assembly to the axle in the axle assembly. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the hub and bearing assembly bolts. Tighten Tighten the hub and bearing to axle bolts to 60 N.m (44 lb ft). 3. Connect the rear ABS wheel speed sensor wire connector. 4. Install the brake drum. 5. Install the tire and wheel assemblies. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Axle Nut ...................................................................................................................................... .................................................. 200 N.m (148 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 4986 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5000 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5005 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5006 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5007 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5008 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5009 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5010 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5011 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5012 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5013 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 5014 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 5015 Inflation Pressure Converrsion (Kilopascals To PSI) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 5016 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 5017 Tires: Description and Operation TREAD WEAR INDICATORS DESCRIPTION The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 72 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). TIRE INFLATION DESCRIPTION When you inflate the tires to the recommended inflation pressures, the factory-installed wheels and tires are designed in order to handle loads to the tire's rated load capacity. Incorrect tire pressures, or under-inflated tires, can cause the following conditions: - Vehicle handling concerns - Poor fuel economy - Shortened tire life - Tire overloading Inspect the tire pressure when the following conditions apply: - The vehicle has been sitting at least 3 hours. - The vehicle has not been driven for more than 1.6 km (1 mi). - The tires are cool. Inspect the tires monthly or before any extended trip. Adjust the tire pressure to the specifications on the tire label. Install the valve caps or the extensions on the valves. The caps or the extensions keep out dust and water. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 5018 Inflation Pressure Converrsion (Kilopascals To PSI) The kilopascal kPa) is the metric term for pressure. The tire pressure may be printed in both kilopascal kPa) and psi. One psi equals 6.9 kPa. Tires with a higher than recommended pressure can cause the following conditions: - A hard ride - Tire bruising - Rapid tread wear at the center of the tire Tires with a lower than recommended pressure can cause the following conditions: - A tire squeal on turns - Hard steering - Rapid wear and uneven wear on the edge of the tread - Tire rim bruises and tire rim rupture - Tire cord breakage - High tire temperatures - Reduced vehicle handling - High fuel consumption - Soft riding Unequal pressure on the same axle can cause the following conditions: - Uneven braking - Steering lead - Reduced vehicle handling Refer to the Tire Placard for specific tire and wheel applications and tire pressures. ALL SEASONS TIRES DESCRIPTION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 5019 Most GM vehicles are equipped with steel belted all-season radial tires as standard equipment. These tires qualify as snow tires, with a higher than average rating for snow traction than the non-all season radial tires previously used. Other performance areas, such as wet traction, rolling resistance, tread life, and air retention, are also improved. This is done by improvements in both tread design and tread compounds. These tires are identified by an M+ S molded in the tire side wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification number. The optional handling tires used on some vehicles now also have the MS marking after the tire size and the TPC specification number. P-METRIC SIZED TIRES DESCRIPTION Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement tires should be of the same tire performance criteria (TPC) specification number including the same size, the same load range, and the same construction as those originally installed on the vehicle. Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection Tires: Service and Repair Tire and Wheel Rotation and Inspection TIRE AND WHEEL INSPECTION AND ROTATION Tires should be rotated every 6,000 to 8,000 miles (10 000 km to 13 000 km). CAUTION: Rust or dirt on a wheel, or on the parts to which it is fastened, can make wheel nuts become loose after a time. The wheel could come off and cause an accident. When you change a wheel, remove any rust or dirt from places where the wheel attaches to the vehicle. In an emergency, you can use a cloth or a paper towel to do this; but be sure to use a scraper or wire brush later, if you need to, to get all the rust or dirt off. 1. Check the tires for abnormal wear or damage. 2. Ensure the spare tire is stored securely. Push, pull, and then try to rotate or turn the tire. If it moves, use the folding wrench to tighten the cable. 3. Rotate the tires to equalize the wear and obtain maximum tire life. 4. When rotating tires, always use the correct rotation pattern shown here. 5. Do not include the compact spare tire in tire rotation. 6. After the tires have been rotated, adjusted the front and rear inflation pressures as shown on the Certification/Tire label. Ensure that all wheel nuts are properly tightened. 7. Make certain that all wheel nuts are properly tightened. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 5022 Tires: Service and Repair Tire and Wheel - Removal and Installation TIRE AND WHEEL REMOVAL AND INSTALLATION TOOLS REQUIRED J 39544-KIT Complete Torque Socket Set CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. NOTE: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. IMPORTANT:Removing wheels can be difficult because of foreign material or a tight fit between the wheel and the hub / rotor. Slightly tap the tire side wall with a rubber mallet in order to remove the wheel. Failure to follow these instructions may result in damage to the wheel. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. REMOVAL PROCEDURE 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. INSTALLATION PROCEDURE CAUTION: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. NOTE: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 5023 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice IMPORTANT:Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten Tighten the nuts in a criss/cross pattern to 140 N.m (100 lb ft). 3. Remove the safety stands and lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 5024 Tires: Service and Repair Tire - Repair TIRE REPAIR Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Rotation and Inspection > Page 5025 Tires: Service and Repair Tire - Mounting and Dismounting TIRE MOUNTING AND DISMOUNTING NOTE: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Deflate the tire completely. NOTE: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 2. Use the tire changer in order to remove the tire from the wheel. IMPORTANT:Rim-clamp European-type tire changers are recommended. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. 4. Apply GM P/N 12345884 (Canadian P/N 5728223) or equivalent to the tire bead and the wheel rim. NOTE: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 5. Use the tire changer in order to install the tire to the wheel. 6. Inflate the tire to the proper air pressure. CAUTION: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa(40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5034 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5035 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5036 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 5041 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5046 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5047 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5048 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheels: Customer Interest Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5053 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5054 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5055 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5056 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5062 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5063 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5064 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 5069 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 5074 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 5075 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5080 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5081 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 5082 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 5087 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5092 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5093 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 5094 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheels: All Technical Service Bulletins Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5103 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5104 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5105 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5106 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5112 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5113 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 5114 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 5119 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 5124 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 5125 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 5130 Wheels: Description and Operation REPLACEMENT WHEELS DESCRIPTION Replace the wheel if any of the following conditions exist: - The wheel exhibits excessive runout. - The wheel is bent. - The wheel is cracked. - The wheel is severely rusted. - The wheel is severely corroded. - The wheel leaks air. IMPORTANT:Air leaks caused by porosity on aluminum wheels are repairable. CAUTION: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. NOTE: The use of non-GM original equipment wheels may cause: Damage to the wheel bearing, the wheel fasteners and the wheel Tire damage caused by the modified clearance to the adjacent vehicle components Adverse vehicle steering stability caused by the modified scrub radius Damage to the vehicle caused by the modified ground clearance Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: - The wheel has elongated bolt holes. - The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. STEEL WHEEL REPAIR DESCRIPTION NOTE: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation Wheels: Service and Repair Tire and Wheel - Removal and Installation TIRE AND WHEEL REMOVAL AND INSTALLATION TOOLS REQUIRED J 39544-KIT Complete Torque Socket Set CAUTION: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident. NOTE: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. IMPORTANT:Removing wheels can be difficult because of foreign material or a tight fit between the wheel and the hub / rotor. Slightly tap the tire side wall with a rubber mallet in order to remove the wheel. Failure to follow these instructions may result in damage to the wheel. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut two turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. REMOVAL PROCEDURE 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. INSTALLATION PROCEDURE CAUTION: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. NOTE: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 5133 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. 2. Install the wheel nuts. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice IMPORTANT:Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten Tighten the nuts in a criss/cross pattern to 140 N.m (100 lb ft). 3. Remove the safety stands and lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 5134 Wheels: Service and Repair Aluminum Wheel - Porosity Repair ALUMINUM WHEEL POROSITY REPAIR 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel.. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. IMPORTANT:Do not damage the exterior surface of the wheel. 8. Use general purpose cleaner such as 3M(R), P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 in) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing Off-Vehicle in Vibration Diagnosis and Correction. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Tire and Wheel - Removal and Installation > Page 5135 Wheels: Service and Repair Aluminum Wheel - Refinishing ALUMINUM WHEEL REFINISHING FINISH DAMAGE EVALUATION PROCEDURE 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. IMPORTANT:If the wheels are chrome-plated, do not re-plate or refinish the wheels. If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for the following conditions: - Corrosion - Scrapes - Gouges 2. Verify the damage is not deeper than what sanding can remove. 3. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 4. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. REFINISHING PROCEDURE 1. Remove the tire and wheel assembly from the vehicle. CAUTION: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: - Lubricants - Wax - Dirt 5. Use plastic media blasting in order to remove the paint from the wheel. IMPORTANT:Do not re-machine the wheel. Do not use chemicals in order to strip the paint from the wheel. 1. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. 2. Mask the wheel mounting surface and the wheel nut contact surface. IMPORTANT:The wheel mounting surface and the wheel nut contact surface must remain free of paint. 3. Follow the paint manufacturer's instructions for painting the wheel. 4. Unmask the wheel. 5. Install a new valve stem. 6. Install the tire to the wheel. IMPORTANT:Use new coated balance weights in order to balance the wheel. 7. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: - Corrosion - Overspray - Dirt 8. Install the tire and wheel assembly to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection Wheel Bearing: Testing and Inspection WHEEL BEARINGS DIAGNOSIS TOOLS REQUIRED J 8001 Dial Indicator The following procedure describes how to inspect the wheel bearing/hub for excessive looseness. If you are inspecting the wheel bearing/hub for excessive runout, refer to Hub/Axle Flange and Wheel Stud Runout Inspection in Vibration Diagnosis and Correction. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Mount and secure the J 8001 to a stand. IMPORTANT:If you are inspecting the FRONT wheel bearing/hub, support the front of the vehicle by the lower control arms in order to load the lower ball joint. 3. Ensure that the J 8001 contacts the vertical surface of the wheel as close as possible to the top wheel stud. 4. Push and pull on the TOP of the tire. 5. Inspect the total movement indicated by the J 8001. 6. If the measurement exceeds 0.127 mm (0.005 in), replace the wheel bearing/hub. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension Wheel Bearing: Service and Repair Front Suspension WHEEL BEARING/HUB REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the drive axle nut. 4. Remove the brake rotor 5. Remove the mounting bolts (1) from the hub and bearing assembly (3). 6. Remove the hub and bearing assembly (1) from the steering knuckle (2) and drive axle shaft. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5141 1. Install the hub and bearing assembly (1) into the steering knuckle (2) and drive axle shaft. 2. Install the hub bearing mounting bolts (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 95 N.m (70 lb ft). 3. Install the drive axle shaft nut. Tighten Tighten the drive axle shaft nut to 200 N.m (148 lb ft). 4. Install the brake rotor. 5. Install the tire and wheel assemblies. 6. Inspect the front wheel alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Suspension > Page 5142 Wheel Bearing: Service and Repair Rear Suspension WHEEL BEARING/HUB REPLACEMENT - REAR REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the brake drum. NOTE: Do not hammer on brake drum as damage to the bearing could result. 4. Disconnect the rear ABS wheel speed sensor wire connector. 5. Remove the hub and bearing assembly bolts 6. Remove the hub and bearing assembly from the axle. INSTALLATION PROCEDURE 1. Install the hub and bearing assembly to the axle in the axle assembly. NOTE: Refer to Fastener Notice in Service Precautions. See: Service Precautions/Vehicle Damage Warnings/Fastener Notice 2. Install the hub and bearing assembly bolts. Tighten Tighten the hub and bearing to axle bolts to 60 N.m (44 lb ft). 3. Connect the rear ABS wheel speed sensor wire connector. 4. Install the brake drum. 5. Install the tire and wheel assemblies. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheel Cover: Customer Interest Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5151 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5152 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5153 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 5154 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels Front/Rear Wheel Squeaking Noises Wheel Cover: All Technical Service Bulletins Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels Front/Rear Wheel Squeaking Noises > Page 5160 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels Front/Rear Wheel Squeaking Noises > Page 5161 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels Front/Rear Wheel Squeaking Noises > Page 5162 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 01-03-10-005C > Oct > 03 > Wheels Front/Rear Wheel Squeaking Noises > Page 5163 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Drive Axle Nut ...................................................................................................................................... .................................................. 200 N.m (148 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 5176 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 5182 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 5183 Wheel Fastener: Specifications WHEEL FASTENER TORQUE Tighten the nuts in a criss/cross pattern to 140 Nm (100 lb. ft.). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 5184 Wheel Nut Torque Sequence Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 5185 Wheel Fastener: Description and Operation METRIC WHEEL NUTS AND BOLTS DESCRIPTION Metric wheel/nuts and bolts are identified in the following way: - The wheel/nut has the word Metric stamped on the face. - The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. - M = Metric - 12 = Diameter in millimeters - 1.5 = Millimeters gap per thread Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension WHEEL STUD REPLACEMENT TOOLS REQUIRED J 43631 Ball Joint Separator REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the hub and bearing assembly. 4. Remove the wheel stud (1) from the hub and bearing assembly (2) using the J 43631. 5. Discard the stud. INSTALLATION PROCEDURE 1. Install the replacement stud into the hub and bearing assembly (2). 2. Add enough washers in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the hub and bearing assembly. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 5188 Wheel Fastener: Service and Repair Rear Suspension WHEEL STUD REPLACEMENT TOOLS REQUIRED J 43631 Ball Joint Separator REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. 2. Remove the tire and the wheel assembly. 3. Remove the brake drum. 4. Remove the wheel stud using the J 43631 NOTE: Do not hammer on brake drum as damage to the bearing could result. 5. Discard the wheel stud. INSTALLATION PROCEDURE 1. Install the new stud from the back side of the hub. 2. Install the four flat washers (3) on the hub. 3. Install the wheel nut with the flat side toward the washers. 4. Tighten the nut until the stud is properly seated in the hub flange. 5. Remove the nut and the washers. 6. Install the brake drum. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 5189 7. Install the tire and the wheel assembly. 8. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Accumulator HVAC: Customer Interest A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5199 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Customer Interest for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5200 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Accumulator HVAC: All Technical Service Bulletins A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5206 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5207 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 5208 Accumulator HVAC: Service and Repair ACCUMULATOR REPLACEMENT (L61) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Reposition the cruise control bracket. with module, if equipped. 3. Remove the 2 nuts holding the bracket for the PCM module. Position the bracket and module out of the way. 4. Remove the refrigerant tubes from the accumulator (1). 5. Discard the O-ring seals. 6. Remove the accumulator bracket (3). 7. Remove the accumulator (1) from the vehicle. INSTALLATION PROCEDURE 1. Install the accumulator (1). IMPORTANT: Add the required amount of new refrigerant oil. Refer to Refrigerant System Capacities (L61). 2. Install the accumulator bracket (3) clamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Technical Service Bulletins > Page 5209 Tighten the bolt to 8 N.m (71 lb in). 3. Install new O-ring seals to refrigerant lines. 4. Install the refrigerant lines to the accumulator. 5. Install the accumulator tube to accumulator and compressor tube to accumulator fitting nuts Tighten Tighten nuts to 35 N.m (26 lb ft). 6. Position the bracket holding the PCM module on to the shock tower. 7. Install the bracket nuts holding the PCM module on to the shock tower. Tighten Tighten the PCM bracket nuts to 10 N.m (89 lb in). 8. Reposition the cruise control bracket if equipped. 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5214 Recirculation Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5215 Air Door Actuator / Motor: Service and Repair RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. 2. Disconnect the wire harness from the recirculation actuator. 3. Remove the 2 screws holding the recirculation actuator housing to the HVAC module assembly. 4. Remove the recirculation actuator from the HVAC module assembly. INSTALLATION PROCEDURE 1. Slide the recirculation actuator on to the module. 2. Install the 2 screws holding the recirculation actuator housing to the HVAC module assembly. 3. Connect the wiring harness to the recirculation actuator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 5216 4. Install the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement Air Door Cable: Service and Repair Mode Control Cable Replacement REMOVAL PROCEDURE 1. Remove the I/P trim plate. 2. Disconnect the mode control cable from the mode door lever. 3. Remove the cable flag retaining screw. 4. Remove the HVAC control assembly. 5. Release the flag from the mode base using the release tab. 6. Remove the flag. 7. Remove the cable end form from the lever post. 8. Remove the temperature control cable. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5221 1. Install the mode control cable to the HVAC control assembly. 2. Snap the flag into the mode base. 3. Snap the cable end form over the lever post. 4. Install the cable to the mode door lever/cam. 5. Install the cable flag and screw to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the HVAC control assembly. 7. Install the I/P trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5222 Air Door Cable: Service and Repair Temperature Control Cable Replacement REMOVAL PROCEDURE 1. Remove the I/P trim plate. 2. Disconnect the temperature control cable from the temperature door lever. 3. Remove the cable flag retaining screw. 4. Remove the HVAC control assembly. 5. Use the tab to release the flag from the HVAC control assembly. 6. Remove the temperature control cable. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Service and Repair > Mode Control Cable Replacement > Page 5223 1. Install the temperature control cable to the HVAC control assembly. 2. Snap the cable flag to the base of the HVAC control assembly. 3. Snap the die cast end form over the lever post. 4. Install the cable cover. 5. Install the cable to the temperature door lever. 6. Install the cable flag and screw to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 7. Install the HVAC control assembly. 8. Install the I/P trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement REMOVAL PROCEDURE 1. Remove the IP trim pad. 2. Remove the air distribution duct screws. 3. Remove the air distribution duct. 4. Remove the right side air distribution duct. INSTALLATION PROCEDURE 1. Position the air distribution duct through the dash braces. 2. Install the air distribution duct and connect to the right side duct. 3. Install the air distribution duct screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the IP trim pad. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 5228 Air Duct: Service and Repair Air Outlet Duct Replacement - Defroster REMOVAL PROCEDURE 1. Remove the IP trim pad. 2. Remove the defroster duct. INSTALLATION PROCEDURE 1. Install the defroster duct. 2. Install the IP trim pad. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 5229 Air Duct: Service and Repair Air Outlet Duct Replacement - Left Defogger REMOVAL PROCEDURE 1. Remove the I/P trim pad. 2. Disconnect the left side window defroster duct from the HVAC module. 3. Remove the defroster duct from the clips. 4. Disconnect the defroster duct from the left side window defogger adapter. 5. Remove the defroster duct from the I/P carrier. 6. Remove the left side window defogger adapter. INSTALLATION PROCEDURE 1. Install the left side window defogger adapter. 2. Install the defroster duct to the I/P carrier. Route the duct through the I/P carrier hole. 3. Push the defroster duct to the clip and seat. 4. Connect the defroster duct to the HVAC module assembly. 5. Connect the defroster duct to the left side window defogger adapter. 6. Install the I/P trim pad. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 5230 Air Duct: Service and Repair Air Outlet Duct Replacement - Right Defogger REMOVAL PROCEDURE 1. Remove the I/P trim pad. 2. Disconnect the right side window defroster duct from the HVAC module assembly. 3. Remove the defroster duct from the clip. 4. Disconnect the defroster duct from the right side window defogger adapter. 5. Remove the defroster duct from the I/P carrier. 6. Remove the right side window defogger adapter. INSTALLATION PROCEDURE 1. Install the right side window defogger adapter. 2. Install the right side defroster duct to the I/P carrier. Route the duct through the I/P carrier hole. 3. Push the defroster duct to the clip and seat. 4. Connect the defroster duct to the HVAC module assembly. 5. Connect the defroster duct to the right side window defogger adapter. 6. Install the IP trim pad. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Floor Air Register: Service and Repair Air Outlet Replacement - Floor REMOVAL PROCEDURE 1. Remove the console. 2. Remove the closeout cover from the air outlet. 3. Reposition the floor carpet aside in order to access the floor outlet duct connections. 4. Remove the floor outlet ducts from the heater outlet cover. 5. Remove the floor outlet ducts. INSTALLATION PROCEDURE 1. Install the floor outlet ducts to the heater outlet cover. 2. Install the floor outlet ducts over the stud and slide them into position. 3. Position the carpet back into place. 4. Install the closeout cover to the air outlet. 5. Install the closeout cover bolts to the air outlet. Tighten Tighten the bolts to 2.3 N.m (20 lb in). 6. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Floor > Page 5235 Air Register: Service and Repair Air Outlet Replacement - Rear Floor REMOVAL PROCEDURE 1. Remove the console. 2. Reposition the floor carpeting to the rear of the front seat. 3. Remove the rear floor ducts (3). INSTALLATION PROCEDURE 1. Install the rear floor ducts (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 2. Install the floor carpeting. 3. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Floor > Page 5236 Air Register: Service and Repair Deflector Replacement - Instrumental Panel Air REMOVAL PROCEDURE 1. Grasp the center of the air deflector outlet. IMPORTANT: The instrument panel (I/P) trim pad should be at room temperature before removal of the air I/P outlet deflector. This will allow the I/P trim pad to be more pliable during removal of the air deflector outlet. 2. Position the tip of a flat-bladed tool between the air deflector housing and the air deflector outlet. With the tip of the flat-bladed tool, gently push the outlet outward from the housing disengaging the retainer. 3. On the opposite side of the deflector, position the tip of a flat-bladed tool between the air deflector housing and the air deflector outlet. With the tip of the flat-bladed tool, gently push the outlet outward from the housing disengaging the retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Floor > Page 5237 4. Remove the air deflector outlet from the housing in the I/P. INSTALLATION PROCEDURE 1. Position the air deflector outlet into the housing in the I/P. 2. Press the air outlet deflector into the housing until fully engaged. 3. Inspect the air deflector outlet for proper movement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the blower motor relay from the electrical center. INSTALLATION PROCEDURE 1. Install the blower motor relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Blower Motor Resistor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5244 Blower Motor Resistor: Service and Repair BLOWER MOTOR RESISTOR ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the blower motor. 2. Disconnect the electrical connection at the blower motor resistor assembly. 3. Remove the blower motor resistor assembly screws. 4. Remove the blower motor resistor assembly. INSTALLATION PROCEDURE 1. Install the blower motor resistor assembly. 2. Install the blower motor resistor assembly screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1 N.m (9 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5245 3. Connect the electrical connector to the blower motor resistor assembly. 4. Install the blower motor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations This vehicle does not have a factory installed cabin filter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Pull back the rear compartment trim from the right rear corner in order to expose the quarter outer panel pressure relief valve. 3. Remove the quarter outer panel pressure relief valve (1). Disengage the tabs from the inside of the rear compartment. Installation Procedure 1. Install the pressure relief valve (1) by sliding the valve into the opening and engaging the tabs. Fully engage the retaining tabs. 2. Install the rear compartment trim. 3. Install the rear bumper fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Air Gap Between The Pulley And The Drive Plate 0.3-0.6 mm (0.012-0.024 in) Air Gap Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5256 A/C Compressor Clutch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5257 Compressor Clutch: Service and Repair COMPRESSOR CLUTCH ASSEMBLY REPLACEMENT (DIRECT MOUNT) TOOLS REQUIRED - J 37872 Universal Spanner Wrench - J 6083 Snap Ring Pliers REMOVAL PROCEDURE 1. Remove the compressor. 2. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. IMPORTANT: Remove the three adjustable dowels from the J 37872 Universal Spanner Wrench. Install three 5/16 x 1 inch bolts in place of the dowels. 3. Remove the compressor clutch plate from the compressor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5258 4. Remove the compressor pulley snap ring using the J 6083. 5. Remove the compressor pulley from the compressor. 6. Remove the compressor clutch coil snap ring using the J 6083. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5259 7. Remove the compressor clutch coil from the compressor. INSTALLATION PROCEDURE 1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air. 2. Install the compressor clutch coil to the compressor. 3. Install the compressor clutch coil snap ring using the J 6083. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5260 4. Install the compressor pulley to the compressor. 5. Install the compressor pulley snap ring using the J 6083. 6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate. 7. Install the compressor clutch plate to the compressor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 5261 8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap. IMPORTANT: Make certain that the drive plate does not drag against the pulley when the pulley is rotated. 9. Install the clutch drive plate bolt. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. 10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. Tighten Tighten the bolt to 12 N.m (9 lb ft). 11. Install the compressor. 12. Leak test the fittings using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE 1. Install the A/C compressor control relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the hood latch support. 3. Remove the nut holding the compressor hose assembly to the condenser. 4. Remove the compressor hose assembly from the condenser. 5. Remove and discard the O-ring seal. 6. Remove the evaporator tube from the condenser. 7. Remove the radiator air upper seal from the radiator. 8. Remove the condenser to radiator bolts (3). 9. Lift the condenser tabs from the clips on the radiator. INSTALLATION PROCEDURE 1. Add the proper amount of refrigerant oil to the new condenser. Install the condenser to the radiator. Ensure the tabs on the condenser are completely seated in the clips on the radiator. 2. Install the condenser to radiator bolts (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 5268 Tighten the condenser bolts to 4 N.m (36 lb in). 3. Install the radiator air upper seal onto the flange on the radiator. 4. Install the evaporator tube to the condenser. 5. Install a NEW O-ring seal to the condenser end of the compressor hose assembly. 6. Install the compressor hose assembly to the condenser. 7. Install the fitting nut for the compressor hose assembly to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 8. Install the hood latch support. 9. Evacuate and recharge the A/C system. 10. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-38-005D > Jan > 06 > A/C - Difficult to Change Modes on Control Control Assembly: Customer Interest A/C - Difficult to Change Modes on Control Bulletin No.: 03-01-38-005D Date: January 12,2006 TECHNICAL Subject: Difficult to Change HVAC Mode or Air Blows Through Upper Vents Only (Replace Foam on HVAC Mode Valve) Models: 2003-2005 Chevrolet Cavalier 2003-2005 Pontiac Sunfire Supercede: This bulletin is being revised to add the 2005 model year. Please discard Corporate Bulletin Number 03-01-38-005C (Section 01 - HVAC). Condition Some customers may comment of difficulty in changing the HVAC (heating, ventilation and air conditioning) mode or that air blows through the upper vents only. Cause This condition may be caused by the foam on the HVAC mode valve (mode door) coming loose. Correction Technicians are to replace the foam on the HVAC mode valve (mode door) using the following procedure: For Chevrolet Vehicles 1. Remove both instrument panel outer trim covers. 2. Remove the instrument panel trim pad. 3. Remove the instrument panel accessory trim plate. 4. Remove the air distributor duct. 5. Install a new piece of foam on the mode door valve, P/N 89018656. Refer to the instruction sheet that is included with the new part for detailed foam installation instructions and part illustrations. 6. Install the air distributor duct. 7. Install the instrument panel accessory trim plate. 8. Install the instrument panel trim pad. 9. Install both instrument panel outer trim covers. 10. Verify proper operation of the HVAC system. For Pontiac Vehicles Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-38-005D > Jan > 06 > A/C - Difficult to Change Modes on Control > Page 5277 1. Remove both instrument panel outer trim covers. 2. Remove the instrument panel upper trim pad. 3. Remove the instrument panel accessory trim plate. 4. Remove the instrument panel trim pad. 5. Remove the air distributor duct. 6. Install a new piece of foam on the mode door valve, P/N 89018656. Refer to the instruction sheet that is included with the new part for detailed foam installation instructions and part illustrations. 7. Install the air distributor duct. 8. Install the instrument panel trim pad. 9. Install the instrument panel accessory trim plate. 10. Install the instrument panel upper trim pad. 11. Install both instrument panel outer trim covers. 12. Verify proper operation of the HVAC system. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 03-01-38-005D > Jan > 06 > A/C - Difficult to Change Modes on Control > Page 5278 Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 03-01-38-005D > Jan > 06 > A/C Difficult to Change Modes on Control Control Assembly: All Technical Service Bulletins A/C - Difficult to Change Modes on Control Bulletin No.: 03-01-38-005D Date: January 12,2006 TECHNICAL Subject: Difficult to Change HVAC Mode or Air Blows Through Upper Vents Only (Replace Foam on HVAC Mode Valve) Models: 2003-2005 Chevrolet Cavalier 2003-2005 Pontiac Sunfire Supercede: This bulletin is being revised to add the 2005 model year. Please discard Corporate Bulletin Number 03-01-38-005C (Section 01 - HVAC). Condition Some customers may comment of difficulty in changing the HVAC (heating, ventilation and air conditioning) mode or that air blows through the upper vents only. Cause This condition may be caused by the foam on the HVAC mode valve (mode door) coming loose. Correction Technicians are to replace the foam on the HVAC mode valve (mode door) using the following procedure: For Chevrolet Vehicles 1. Remove both instrument panel outer trim covers. 2. Remove the instrument panel trim pad. 3. Remove the instrument panel accessory trim plate. 4. Remove the air distributor duct. 5. Install a new piece of foam on the mode door valve, P/N 89018656. Refer to the instruction sheet that is included with the new part for detailed foam installation instructions and part illustrations. 6. Install the air distributor duct. 7. Install the instrument panel accessory trim plate. 8. Install the instrument panel trim pad. 9. Install both instrument panel outer trim covers. 10. Verify proper operation of the HVAC system. For Pontiac Vehicles Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 03-01-38-005D > Jan > 06 > A/C Difficult to Change Modes on Control > Page 5284 1. Remove both instrument panel outer trim covers. 2. Remove the instrument panel upper trim pad. 3. Remove the instrument panel accessory trim plate. 4. Remove the instrument panel trim pad. 5. Remove the air distributor duct. 6. Install a new piece of foam on the mode door valve, P/N 89018656. Refer to the instruction sheet that is included with the new part for detailed foam installation instructions and part illustrations. 7. Install the air distributor duct. 8. Install the instrument panel trim pad. 9. Install the instrument panel accessory trim plate. 10. Install the instrument panel upper trim pad. 11. Install both instrument panel outer trim covers. 12. Verify proper operation of the HVAC system. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 03-01-38-005D > Jan > 06 > A/C Difficult to Change Modes on Control > Page 5285 Warranty Information Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Assembly: > 04-01-37-001 > Jan > 04 > A/C Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Assembly: > 04-01-37-001 > Jan > 04 > A/C - Control Knob Replacement Availability Control Assembly: All Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 HVAC Control Assembly C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 > Page 5297 HVAC Control Assembly C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > HVAC Control Assembly C1 > Page 5298 HVAC Control Assembly C3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC Control Assembly Replacement Control Assembly: Service and Repair HVAC Control Assembly Replacement HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the accessory trim plate. 2. Remove the HVAC control assembly retaining screws. 3. Pull the HVAC control assembly (1) away from the I/P. 4. Disconnect the electrical connections. 5. Disconnect the mode control cable. 6. Disconnect the temperature control cable. INSTALLATION PROCEDURE 1. Connect the electrical connections. 2. Connect the mode control cable. 3. Connect the temperature control cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC Control Assembly Replacement > Page 5301 4. Install the HVAC control assembly (1) to the I/P. 5. Install the HVAC control assembly retaining screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 2 N.m (18 lb in). 6. Install the accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > HVAC Control Assembly Replacement > Page 5302 Control Assembly: Service and Repair HVAC Control Lamp Replacement HVAC CONTROL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel accessory trim plate. 2. Remove the screws from the HVAC control. 3. Pull the HVAC control away from the instrument panel. 4. Remove the bulbs/sockets (1) from the HVAC control. 5. Remove the bulbs from the sockets. INSTALLATION PROCEDURE 1. Install the bulbs to the sockets (1). 2. Install the bulbs/sockets (1) to the HVAC control. 3. Install the HVAC control to the instrument panel. 4. Install the screws to the HVAC control. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the HVAC control screws 2 N.m (18 lb in). 5. Install the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. - For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). - For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 5. Cap or tape the A/C refrigerant components. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 6. Discard the O-ring seal. INSTALLATION PROCEDURE 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. IMPORTANT: DO NOT reuse O-ring seals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 5308 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. - For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. - For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 5309 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. 4. Discard the sealing washer. IMPORTANT: DO NOT reuse sealing washer. INSTALLATION PROCEDURE 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. IMPORTANT: Flat washer type seals do not require lubrication. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5318 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5319 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5325 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 5326 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5327 Evaporator Core: Service and Repair REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the heat stakes and the screws from the upper case assembly. 3. Remove the cam cable and the screw. 4. Remove the upper case assembly. 5. Remove the heat stakes and the screws from the heater cover. 6. Remove the heater cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5328 7. Remove the evaporator core. INSTALLATION PROCEDURE 1. If you are installing a new evaporator core. drain oil from evaporator core measure and add the same quantity of refrigerant oil to the new evaporator core. 2. Install the evaporator core. 3. Install the upper case assembly and the screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1 N.m (9 lb in). 4. Install the cam cable and the screw. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5329 5. Install the heater cover and the screws and sealant. Tighten Tighten the screws to 1 N.m (9 lb in). 6. Install the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair EXPANSION (ORIFICE) TUBE REPLACEMENT TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 26549-E Orifice Tube Remover REMOVAL PROCEDURE 1. Remove the evaporator tube. 2. Remove the evaporator tube from the condenser tube. 3. Use the J 26549-E in order to remove the expansion orifice tube. 4. Inspect the expansion (orifice) tube for the following conditions and clean or replace with a new tube as indicated: - Broken plastic frame, replace tube. - Filter screen (1,2) torn, damaged or plugged with fine gritty material, replace tube. - Brass orifice tube (3) damaged or plugged, replace tube. - Filter screen (1) coated with metal chips, flakes, or slivers-coating may be removed with low pressure shop air and reused if cleaned satisfactorily. If reusing the tube, install a new O-ring (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 5333 1. Lightly coat the new orifice tube O-ring seal (4) with mineral base 525 viscosity refrigerant oil. 2. Remove the cap or tape from the evaporator tube. 3. Using needle-nose pliers, CAREFULLY grasp the edge of the expansion (orifice) tube (short filter screen (2) inlet side of tube) without touching the filter screen and insert the tube (long filter screen (1) outlet side first) fully into the evaporator line. 4. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the tube fittings. 5. Install a new O-ring seal on the condenser tube. Coat the O-ring seal with 525 viscosity refrigerant oil. 6. Install the evaporator tube. 7. Evacuate and recharge the A/C system. 8. Leak test the fittings of the component using the J 39400-A. 9. Install the hood close out filler panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 5338 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 5339 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5340 Heater Core: Service and Repair HEATER CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Remove the heat stakes and the screws from the heater cover case. 3. Remove the heater cover case. 4. Remove the heater core from the HVAC module assembly. INSTALLATION PROCEDURE 1. Install the heater core to the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5341 2. Install the heater core cover case. 3. Install the heater core cover case screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1 N.m (9 lb in). 4. Install the HVAC module assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) Heater Hose: Service and Repair Heater Hose Replacement - Inlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the inlet heater hose (1) from the inlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the inlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the inlet heater hose (2) to the inlet port of the heater core. 2. Lower the vehicle. 3. Connect the inlet heater hose to the inlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet (L61) > Page 5346 Heater Hose: Service and Repair Heater Hose Replacement - Outlet (L61) TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the engine coolant. 2. Use the J 38185 in order to reposition the heater hose clamps. 3. Disconnect the outlet heater hose (2) from the outlet port of the engine. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Use the J 38185 to disconnect the outlet heater hose from the heater core. INSTALLATION PROCEDURE 1. Connect the outlet heater hose (1) to the outlet port of the heater core. 2. Lower the vehicle. 3. Connect the outlet heater hose to the outlet port of the engine. 4. Use the J 38185 in order to reposition the heater hose clamps. 5. Fill the engine coolant. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Removal High Pressure Safety Valve HVAC: Service and Repair Removal COMPRESSOR PRESSURE RELIEF VALVE INSTALL (CVC-DIRECT MOUNT) 1. Support the A/C compressor. 2. Remove the pressure relief valve from the A/C compressor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Removal > Page 5351 High Pressure Safety Valve HVAC: Service and Repair Installation COMPRESSOR PRESSURE RELIEF VALVE INSTALL (CVC-DIRECT MOUNT) 1. Clean the pressure relief valve seat area on the A/C compressor. 2. Lubricate the O-ring of the new pressure relief valve with clean refrigerant oil. 3. Install the new pressure relief valve into the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the pressure relief valve to 7 N.m (60 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Hose/Line HVAC: Customer Interest A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5360 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5361 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise Hose/Line HVAC: All Technical Service Bulletins A/C - Underhood Growling/Rattling Noise Bulletin No.: 03-01-38-012A Date: March 02, 2004 TECHNICAL Subject: Underhood Rattle Or Growl Noise With A/C On (Reposition A/C System Component to Eliminate Ground Out) Models: 2003-2004 Chevrolet Cavalier 2003-2004 Pontiac Sunfire with 2.2L Engine (VIN F - RPO L61) Supercede: This bulletin is being revised to add 2004 model year. Please discard Corporate Bulletin Number 03-01-38-012 (Section 01 - HVAC). Condition Some customers may comment on an underhood rattle or growl noise with the air conditioning (A/C) on. Cause The A/C system components may be grounding out at various locations underhood. Correction Reposition the A/C system components identified in each of the corrections described below: Correction 1 The A/C liquid line may be in contact with the cooling system purge tank. Reposition the liquid line away from the cooling system purge tank. Refer to the arrow in the illustration above for the location of the ground out. Correction 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5367 The accumulator mounting bracket bolt may contact the right strut tower sheet metal. Add another washer under the head of the accumulator mounting bracket bolt. This will provide extra clearance between the tip of the bolt and the strut tower. Refer to the arrow in the illustration above for the location of the ground out. Correction 3 The accumulator may contact the bottom of the PCM (Powertrain Control Module). Loosen the accumulator mounting bracket bolt and push the accumulator down and then retighten the mounting bracket bolt. This will increase the clearance between the PCM bracket and the accumulator. Refer to the arrow in the illustration above for the location of the ground out. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 03-01-38-012A > Mar > 04 > A/C - Underhood Growling/Rattling Noise > Page 5368 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement (L61) TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the compressor hose assembly to the compressor bolt. 4. Remove the compressor hose assembly from the compressor. 5. Remove and discard the sealing washers. 6. Lower the vehicle. 7. Remove the hood close out filler panel. 8. Reposition the cruise control module out of the way, if equipped. 9. Remove the two nuts holding the bracket for the PCM Module. Position the bracket and module out of the way. 10. Disconnect the refrigerant pressure sensor electrical connector. 11. Remove the nut holding the compressor hose assembly fitting to the condenser. 12. Remove the compressor hose assembly from the condenser. 13. Remove and discard the O-ring seal. 14. Remove the fitting nut for the compressor hose assembly to accumulator. 15. Remove the compressor hose assembly from the accumulator (1). 16. Remove and discard the O-ring seals. 17. Remove the compressor hose assembly (2) from the vehicle. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5371 1. Install a new O-ring seal to the accumulator end of the compressor hose assembly. 2. Install the compressor hose assembly and the fitting nut to the accumulator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fitting nut to 35 N.m (26 lb ft). 3. Install a new O-ring seal to the condenser end of the compressor hose assembly. 4. Install the compressor hose assembly to the condenser. 5. Install the fitting nut for the compressor hose assembly to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 6. Install new sealing washers to the compressor ports. 7. Install the compressor hose assembly to the compressor. 8. Install the nut holding the compressor hose assembly to the compressor. Tighten Tighten the nut to 16 N.m (12 lb ft). 9. Lower the vehicle. 10. Connect the refrigerant pressure sensor electrical connector. 11. Position the bracket holding the PCM Module on to the shock tower. 12. Install the bracket nuts holding the PCM Module on to the shock tower. Tighten Tighten the nuts to 10 N.m (89 lb in). 13. Reposition the cruise control module. 14. Install the hood close out filler panel. 15. Evacuate and recharge the A/C system. 16. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5372 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 38185Hose Clamp Pliers REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Remove the hood close out filler panel. 3. Use the J 38185 in order to reposition the hose clamps. Remove the coolant surge tank hoses from the surge tank. 4. Remove the nut connecting the evaporator tube to the condenser. 5. Discard the O-ring seal. 6. Remove the tube from the retaining clip (6) located on the body side rail 7. Remove the accumulator tube. 8. Raise the vehicle.Refer to Vehicle Lifting. 9. Remove the evaporator tube from the evaporator. 10. Discard the O-ring seals. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5373 11. Lower the vehicle. 12. Remove the evaporator tube (4). INSTALLATION PROCEDURE 1. Install the evaporator tube (4). 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Install the evaporator tube to the evaporator. Use new O-ring seals. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fitting to 24 N.m (18 lb ft). 4. Lower the vehicle. 5. Install the tube to the retraining clip (6) located on the body side rail (2.4L only). 6. Install the evaporator tube to the condenser (3). Use the new O-ring seals. Tighten Tighten the nut to 16 N.m (12 lb ft). 7. Install the accumulator tube. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5374 8. Install the coolant surge tank hoses to the surge tank. Use the J 38185 in order to reposition the hose clamps. 9. Install the hood close out filler panel. 10. Evacuate and charge the A/C system. 11. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5375 Hose/Line HVAC: Service and Repair Accumulator Tube Replacement TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Reposition the cruise control module out of the way, if equipped. 3. Remove the 2 nuts holding the bracket for the PCM Module. Position the bracket and module out of the way. 4. Remove the accumulator tube fitting nut from the accumulator. Use a back-up wrench on the evaporator core fitting. 5. Remove the accumulator tube fitting nut from the evaporator core. 6. Remove the accumulator tube. 7. Remove and discard the O-rings. INSTALLATION PROCEDURE 1. Install new O-rings on both ends of the accumulator tube. 2. Install the accumulator tube to the accumulator and the evaporator core. 3. Install the accumulator tube fitting nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 35 N.m (26 lb ft). 4. Reposition the cruise control module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Compressor Hose Assembly Replacement (L61) > Page 5376 5. Position the bracket holding the PCM module on to the shock tower. 6. Install the bracket nuts holding the PCM module on to the shock tower. Tighten Tighten the nuts to 10 N.m (89 lb in). 7. Evacuate and recharge the A/C system. 8. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. 2. Recover the refrigerant. 3. Remove the bolt connecting the evaporator lines to the evaporator. 4. Remove the evaporator lines from the evaporator. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Use the J 38185 in order to reposition the hose clamps. 7. Disconnect the heater hoses from the heater core. 8. Lower the vehicle. 9. Remove the evaporator case drain tube. 10. Remove the I/P carrier. 11. Disconnect the wiring harness from the cross vehicle beam (1). 12. Remove the attaching bolts from the right and left side of the HVAC module. 13. Remove the bolts (2) from the cross vehicle beam. 14. Remove the cross vehicle beam (1) from the front of the vehicle. IMPORTANT: Place the steering column in the straight tilt position using the tilt lever. 15. Remove the floor air outlet. 16. Disconnect the wiring harness from the HVAC module assembly. 17. Disconnect the electrical connections at the following locations: - The blower motor - The blower resistor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 5380 18. Remove the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines. Remove the HVAC module assembly screw (2) from the mounting bracket (1). 19. Remove the module from the vehicle. IMPORTANT: Do not tilt the HVAC module assembly, or coolant may leak out. INSTALLATION PROCEDURE 1. Install the HVAC module assembly. Align the mounting bracket (1) to the hole. Install the screw (2) to the mounting bracket. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 5381 Tighten Tighten the bolt to 2 N.m (18 lb in). 2. Install the HVAC module attaching bolts near the heater hoses and the A/C evaporator lines. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Connect the electrical connections at the following locations: - The blower motor - The blower resistors 4. Connect the wiring harness to the HVAC module assembly. 5. Install the floor air outlet. 6. Install the cross vehicle beam (1) to the front of the dash. 7. Install the bolts (2) and the studs (3) to the cross vehicle beam (1). Tighten Tighten the bolts and the studs to 10 N.m (89 lb in). 8. Install the support bolts on the right and left side of the HVAC module. Tighten Tighten the fittings to 2 N.m (18 lb in). 9. Connect the wiring harness to the cross vehicle beam (1). 10. Install the I/P carrier. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 5382 11. Raise and support the vehicle. 12. Install the evaporator case drain tube. 13. Connect the heater hoses to the heater core. 14. Use the J 38185 in order to reposition the hose clamps. 15. Lower the vehicle. 16. Connect the evaporator tube to the evaporator. Tighten Tighten the fittings to 24 N.m (18 lb ft). 17. Evacuate and recharge the A/C system. 18. Leak test the fittings of the component using J 39400-A. 19. Fill the cooling system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 5387 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 5388 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant R134a ........................................................................................................................................................... 0.68 kg (1.5 lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5391 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5392 Refrigerant: Service Precautions 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. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a 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. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 5393 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector 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. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a 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. NOTE: - 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. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - 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. - 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 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities (L61) for the correct amount. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Installation 1. Recover and recharge the A/C system. IMPORTANT: The in-line filter, AC Delco P/N 15-1760 must be installed to the A/C evaporator tube (liquid line) between the condenser and the evaporator. The installation of this in-line filter eliminates the need for flushing. 2. Remove the evaporator tube. 3. Remove and discard the existing orifice tube. IMPORTANT: The liquid filter, AC Delco P/N 15-1760 will have an orifice contained in it. 4. Wipe the A/C line with a clean cloth before cutting. 5. Make two marks 38 mm (1.5 in) apart on the liquid line. 6. Using the line cutter, cut the liquid line at the marked position and remove any burrs. IMPORTANT: Do not allow metal burrs from cutting the liquid line from dropping into the line and causing contamination. 7. Remove the nuts, the ferrules and the O-rings from the in-line filter. 8. Push the nuts and ferrules over each of the liquid line halves. IMPORTANT: Do not install the O-rings at this step. 9. Install the ferrules with the small end toward the nut. 10. Install the liquid line into the in-line filter making sure to bottom it out. 11. While holding liquid line bottomed-out in filter, tighten the nuts securely. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 15 N.m (11 lb ft). 12. Disassemble the filter from the liquid line. 13. Lubricate the O-rings with clean 525 viscosity refrigerant oil and install them onto the liquid line. 14. Install the liquid line into the filter bottoming it out. 15. While holding liquid line bottomed-out in filter, tighten the nuts securely. Tighten Tighten the nuts to 15 N.m (11 lb ft). 16. Install the evaporator tube. 17. Evacuate, charge and leak test the system. 18. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Service and Repair > Air Conditioning (A/C) Refrigerant Filter Installation > Page 5398 Refrigerant Filter: Service and Repair Air Conditioning (A/C) Refrigerant Filter Replacement REMOVAL PROCEDURE 1. Recover the refrigerant. 2. Loosen the A/C refrigerant filter nuts. IMPORTANT: The nuts and the ferrules will remain on the line. Do not try to remove. 3. Remove the A/C refrigerant filter. INSTALLATION PROCEDURE 1. Lubricate the O-rings with clean 525 viscosity refrigerant oil and install them onto the evaporator tube. 2. Install the A/C refrigerant filter with the arrow pointing toward the evaporator. 3. Ensure that the liquid line is bottomed out in the filter. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the filter nuts to 15 N.m (11 lb ft). 4. Evacuate and recharge the A/C system. 5. Leak test the fittings of the component. Using the J 39400-A 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY ACCUMULATOR REPLACEMENT ..................................................................................................................................................... 45 ml (1.5 oz) NOTE: Add PAG oil equal to the amount of oil drained from the old accumulator plus the specified additional amount. COMPRESSOR REPLACEMENT ......................................................................................................................................................... 75 ml (2.5 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. The Delphi CVC6 service compressor is precharged with 148.0 ml (5 oz) of PAG oil. CONDENSER REPLACEMENT ............................................................................................................................................................ 30 ml (1.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. EVAPORATOR REPLACEMENT ......................................................................................................................................................... 30 ml (1.0 oz) NOTE: If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. TOTAL SYSTEM PAG OIL CAPACITY ............................................................................................................................................ 147 ml (5.0 oz) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5405 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 5406 Refrigerant Oil: Service and Repair A/C REFRIGERANT SYSTEM OIL CHARGE REPLENISHING If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities (L61). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Right Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5410 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5411 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connection from the sensor. 2. Remove the A/C refrigerant pressure sensor. Discard the O-ring seal. IMPORTANT: The sensor is mounted on a service fitting. Do not discharge the system. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sensor to 5 N.m (44 lb in). 3. Connect the electrical connection to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair Blower Motor Relay: Service and Repair REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the blower motor relay from the electrical center. INSTALLATION PROCEDURE 1. Install the blower motor relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Remove the electrical center cover. 2. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE 1. Install the A/C compressor control relay to the electrical center. 2. Install the electrical center cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Right Side Of Engine Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5423 A/C Refrigerant Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 5424 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the electrical connection from the sensor. 2. Remove the A/C refrigerant pressure sensor. Discard the O-ring seal. IMPORTANT: The sensor is mounted on a service fitting. Do not discharge the system. INSTALLATION PROCEDURE 1. Install the new O-ring seal. 2. Install the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sensor to 5 N.m (44 lb in). 3. Connect the electrical connection to the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair Service Port HVAC: Service and Repair SERVICE PORTS REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the system. 2. Remove the service ports. INSTALLATION PROCEDURE 1. Install a new O-ring seal. 2. Install the service fitting to the compressor hose assembly. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the service port to 12 N.m (106 lb in). 3. Evacuate and recharge the refrigerant system. 4. Leak test the fittings of the component using the J 39400-A. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Proper operation of the 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 in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If any damage is detected, replace the component. If any damage to the mounting points or mounting hardware is detected, repair the component or replace the hardware as needed. Steering column - Perform the steering column accident damage inspection procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - I/P Knee Bolsters - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - I/P brackets, braces, etc. - 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. - I/P Cross Car Beam - Inspect for bending, twisting, buckling, or any other type of damage. - I/P Mounting Points and Brackets - Inspect for bending, twisting, buckling, or any other type of damage. - Seats and Seat Mounting Points - Inspect for bending, twisting, buckling, or any other type of damage. Frontal Inflator Module Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. Inflatable restraint front end sensor - Inflatable restraint I/P module - Inflatable restraint steering wheel module - Inflatable restraint sensing and diagnostic module (SDM) Perform additional inspections on the following components. Inflatable restraint steering wheel module coil and coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points and mounting hardware for the inflatable restraint I/P module, steering wheel module, and SDM - Inspect for any damage and repair or replace each component as needed. Side Inflator Module Deployment - Component Replacement and Inspections After a collision involving a side inflator module deployment, replace the following components on the side of the impact. Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint side impact sensor (SIS) - Inflatable restraint side impact module Perform additional inspections on the following components. Mounting points or mounting hardware for the inflatable restraint SIS and side impact module on the side of the impact - Inspect for any damage and repair or replace each component as needed. - Mounting points or mounting hardware for the inflatable restraint SDM - Inspect for any damage and repair or replace each component as needed. Sensor Replacement Guidelines The front end sensor and SIS replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged. Replace the sensor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5433 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 5434 Repairs and Inspections Required After a Collision: Service and Repair Steering Column STEERING COLUMN ACCIDENT DAMAGE INSPECTION Vehicles involved in accidents involving the following conditions may also have a damaged or misaligned steering column: - Frame damage - Major body or sheet metal damage - Where the steering column has been impacted - Where supplemental inflatable restraint systems deployed Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and inspected for any loose conditions when pushed or pulled by hand. Observe how the bracket is attached to the jacket assembly. - If the capsules are not securely seated and the bracket is bolted to the jacket assembly, replace only the bracket. - If the capsules are not securely seated and the bracket is welded to the jacket assembly, replace only the jacket assembly. Inspect for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. Replace the jacket assembly if the measured dimensions are not within specifications. Visually inspect the steering shaft for sheared injected plastic. If the steering shaft shows sheared plastic, replace the steering shaft. Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked. Using a dial indicator (1) at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.0625 in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5440 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5441 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5442 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5443 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5444 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5445 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5446 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5447 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5448 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5449 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5450 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5451 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5452 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5453 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5454 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5455 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5456 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5457 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5458 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5459 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5460 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5461 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5462 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5463 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5464 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5465 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESS The inflatable restraint wiring harnesses connect the sensing and diagnostic module (SDM), inflator modules, electronic frontal sensor, deployment loops, and the Class 2 serial data circuit together using weather pack connectors. SIR system connectors are yellow in color for easy identification. When repairing SIR system wiring harnesses, follow the proper testing and wiring repair procedures. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Inflatable Restraint Modules And SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5473 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5474 Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5475 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5476 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5477 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5478 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM utilizes internal sensors along with the electronic frontal sensor (EFS), mounted left of the hood latch. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that Ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5479 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the connector position assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5480 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (1) horizontally to the floor pan (3). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: If the old mounting fasteners are damaged, refer to the additional repair procedures at the end of this step. Tighten Tighten the fasteners to 14 N.m (124 lb in). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) studs and/or fasteners are damaged to the extent that the SDM can no longer be properly mounted. First Repair 4.1. Discard the old fastener. 4.2. Use a new fastener GM P/N 10156138. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 14 N.m (124 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5481 Second Repair 4.1. Discard the old fastener. 4.2. Use a larger fastener GM P/N 10267482 with washer GM P/N 11500305. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 15 N.m (11 lb ft). 5. Install the SDM wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. 10. If you replaced the SDM, perform the following procedure in order to update the BCM with the new SDM part number: 10.1. Install a scan tool. IMPORTANT: The AIR BAG indicator may remain ON after the SDM is replaced. After programming the SDM part number into the BCM, cycle the ignition switch OFF and ON. This turns OFF the AIR BAG indicator and clears the DTC. 10.2. Select the Special Functions option from the SIR Menu and press enter. 10.3. Select the Setup SDM Part Number in BCM option and press enter. 10.4. Follow the procedure on the scan tool display. 10.5. Cycle the ignition switch OFF and ON. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of two or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the driver deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories attached to the steering wheel depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5485 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR System. Refer to SIR Disabling and Enabling Zone 3. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel nut. 4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment during installation. 5. Remove the steering wheel from the steering shaft. 6. On vehicles with a tilt column, pull the tilt lever straight out from the steering column. 7. Remove the tilt lever assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5486 8. Remove 2 TORX(r) head screws (1) from the lower shroud (2). 9. Remove the lower shroud (2). 10. Remove 2 TORX(r) head screws (2) from the upper shroud (1). 11. Remove the upper shroud (1). 12. Remove the wire harness straps from the steering wheel column wire harness. 13. Remove the retaining ring (3). 14. Remove the SIR coil (4) from the steering shaft. 15. If replacing, discard the SIR coil. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5487 1. To install the SIR coil, perform the following procedure: 1.1. Aim the wheels straight ahead. 1.2. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 O'clock position. 2. If centering is required, follow the instructions on the notice (1) of the coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. If the SIR coil does not come with a centering tab, you must center the SIR coil. 3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam assembly (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5488 4. Slide the new SIR coil (4) onto the steering shaft assembly (2). IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. 5. Firmly seat the retaining ring (3) into the groove on the steering shaft assembly (2). 6. Remove and discard the centering tab from the new SIR coil (4). 7. Install the upper shroud (1) and secure by using 2 TORX(r) head screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5489 8. Install the lower shroud (2) and secure by using 2 TORX(r) head screws (1). 9. Verify that the tabs on the lower shroud (1) engage with the tabs on the upper shroud (2). Snap the tabs together. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. On vehicles with a tilt column, align the tilt lever into the steering column. 11. Slide the tilt lever handle into the steering column until the handle locks into position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Page 5490 12. Feed the wiring through the steering wheel. 13. Align the steering wheel with the mark on the steering shaft. Install the steering wheel onto the shaft. 14. Install the nut for the steering wheel. Tighten Tighten the nut to 41 N.m (30 lb ft). 15. Install the inflatable restraint steering wheel module. 16. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: Customer Interest Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: All Technical Service Bulletins Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel Discriminating Sensor And Steering Wheel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 5506 Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 5507 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5508 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5509 Inflatable Restraint Side Impact Sensor - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5510 Inflatable Restraint Side Impact Sensor - Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5511 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 5512 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on some vehicles to supplement SIR system performance. The EFS is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the EFS to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. INFLATABLE RESTRAINT SIDE IMPACT SENSORS (SIS) The side impact sensors (SIS) contain a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant side inflator module deployment. Each SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the side air bags. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the pushpin retainers from the hood close out panel. 3. Remove the hood close out panel from the vehicle. 4. Remove the connector position assurance (CPA) from the wiring harness connector. 5. Disconnect the wiring harness connector from the sensor (1). 6. Remove the mounting bolts (2) from the sensor (1). 7. Remove the sensor (1) from the hood latch support bracket (3). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5515 1. Install the sensor (1) to the hood latch support bracket (3). 2. Install the mounting bolts (2) to the sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the wiring harness connector to the sensor (1). 4. Install the CPA to the wiring harness connector. 5. Install the hood close out panel to the vehicle. 6. Install the pushpin retainers to the hood close out panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5516 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Sedan) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the center pillar upper trim. 3. Loosen the bolts (2) on the inflatable restraint side impact sensor. 4. Remove the inflatable restraint side impact sensor from the center pillar (1). 5. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 6. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5517 1. Connect the side impact sensor connector (4). 2. Install the CPA (3) to the side impact sensor connector (4). 3. Remove any dirt, grease, or other impurities from the mounting surface. 4. Install the side impact sensor to the center pillar (1). 5. Align the locating pin on the sensor to the opening in the center pillar (1). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar upper trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5518 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Coupe) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 or to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the door trim panel. 3. Remove enough of the water deflector to access the side impact sensor (1). 4. Loosen the bolts (2) on the inflatable restraint side impact sensor (1). 5. Remove the inflatable restraint side impact sensor (1) from the door (4). 6. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 7. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5519 2. Connect the side impact sensor connector (4). 3. Install the CPA (3) to the side impact sensor connector (4). 4. Install the side impact sensor (1) to the door (4). 5. Align the locating pin on the sensor (1) to the opening in the door (4). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the water deflector to the door. 7. Install the door trim panel. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations Inflatable Restraint Modules And SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5527 Side Air Bag: Diagrams Inflatable Restraint Side Impact Module - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5528 Inflatable Restraint Side Impact Module - Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5529 Side Air Bag: Service Precautions CAUTION: When carrying an undeployed inflator module: Do not carry the inflator module by the wires or connector. - Make sure the air bag opening points away from you. - When storing an undeployed inflator module: Make sure the air bag opening points away from the surface on which the inflator module rests. - Provide free space for the air bag to expand in case of an accidental deployment. - When storing a steering column, do not rest the column with the air bag opening facing down and the column vertical. Lay the column on its side. - Failure to observe these guidelines may result in personal injury. - Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: The seat cushion frame - The seat recliner, if equipped - The seat adjuster - The seat back frame - Failure to do so may cause future personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5530 Side Air Bag: Description and Operation SIDE SIR SYSTEM DESCRIPTION The side impact SIR system consists of the following components: AIR BAG indicator located in the instrument panel cluster (IPC) - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint side impact module - LF - Inflatable restraint side impact module - RF - Inflatable restraint side impact sensor (SIS) - LF - Inflatable restraint side impact sensor (SIS) - RF - Inflatable restraint wiring harnesses The side impact modules are located in the outside portion for the front seat backs. The side impact modules consist of a housing, inflatable air bag, initiating device, and a canister of gas generating material. The initiator is part of the side impact module deployment loop. When a side impact of sufficient force occurs, the SIS detects the impact and sends a signal to the SDM. The SDM compares the signal received from the SIS to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the side deployment loop, deploying the inflator module. The SDM, side impact modules, and the connecting wires make up the side deployment loops. The SDM continuously monitors the side deployment loops for malfunctions and commands the IPC to turn the AIR BAG indicator ON if a fault is present. Each side impact module is equipped with a shorting bar located in the connector of the module. The shorting bar shorts the side impact module deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. INFLATABLE RESTRAINT SIDE IMPACT MODULES The side impact modules consist of a housing, an inflatable air bag, the initiator, a canister of gas generating materials, and in some cases, stored compressed gas. The initiator is part of the inflator module deployment loop. When the vehicle is involved in a collision of sufficient force, the SDM causes current to flow through the deployment loops to the initiator. Current passing through the initiator ignites the material in the canister producing a rapid generation of gas and the release of compressed gas, if present. The gas produced from this reaction rapidly inflates the inflator module. Once the inflator module is inflated, it quickly deflates through the vent holes and/or the fabric. Each inflator module is equipped with a shorting bar that is located in the connector of the inflator module. The shorting bar shorts the inflator modules circuitry to prevent unwanted deployment of the inflator module when the connector is disconnected. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5531 Side Air Bag: Service and Repair INFLATABLE RESTRAINT SIDE IMPACT MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7 or to SIR Disabling and Enabling Zone 9. CAUTION: When carrying an undeployed inflator module: Do not carry the inflator module by the wires or connector. - Make sure the air bag opening points away from you. - When storing an undeployed inflator module: Make sure the air bag opening points away from the surface on which the inflator module rests. - Provide free space for the air bag to expand in case of an accidental deployment. - When storing a steering column, do not rest the column with the air bag opening facing down and the column vertical. Lay the column on its side. - Failure to observe these guidelines may result in personal injury. 1. If the air bag has been deployed, visually inspect seat and replace any damaged parts. CAUTION: Following the deployment of a side impact air bag, inspect the following parts for damage. Replace these parts if necessary: The seat cushion frame - The seat recliner, if equipped - The seat adjuster - The seat back frame - Failure to do so may cause future personal injury. 1. Remove enough of the seat back cover to gain access to the inflator module mounting nuts. 2. Remove the mounting nuts (1) from the inflator module. 3. Remove the inflator module from the seat back frame (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5532 4. Remove the connector position assurance (CPA) (3) from the inflator module electrical connector (2). 5. Disconnect the electrical connector (2) from the inflator module (1). 6. Remove the inflator module (1) from the vehicle. 7. 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 and Scrapping. INSTALLATION PROCEDURE 1. Position the inflator module (1) into the vehicle. 2. Connect the electrical connector (2) to the inflator module (1). 3. Install the CPA (3) to the inflator module electrical connector (2). 4. Install the inflator module to the seat back frame (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 5533 5. Install the mounting nuts (1) to the inflator module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 9 N.m (80 lb in). 6. Install the seat back cover. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7 or to SIR Disabling and Enabling Zone 9. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM is supplied with Ignition 1 voltage and the IPC flashes the AIR BAG indicator seven times. While flashing the indicator, the SDM conducts test on all SIR system components and circuits. If no malfunctions are detected the SDM will communicate with the IPC through the Class 2 serial data circuit and command the AIR BAG indicator OFF. The SDM provides continuous monitoring of the air bag circuits by conducting a sequence of checks. If a malfunction is detected the SDM will store a diagnostic trouble code (DTC) and command the AIR BAG indicator ON. The presence of a SIR system malfunction could result in non-deployment of the air bags. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation DRIVER AND PASSENGER KNEE BOLSTERS The knee bolsters are designed to help restrain the lower torsos of front seat occupants by absorbing energy through the front seat occupants' upper legs. In a frontal collision the front seat occupants' legs may come in contact with the knee bolsters. The knee bolsters are designed to crush or deform absorbing some of the impact, which helps to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damage after a collision. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations Inflatable Restraint Modules And SDM Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5548 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5549 Inflatable Restraint Sensing And Diagnostic Module (SDM) C1 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5550 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5551 Inflatable Restraint Sensing And Diagnostic Module (SDM) C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5552 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5553 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM utilizes internal sensors along with the electronic frontal sensor (EFS), mounted left of the hood latch. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors. The SDM compares the results of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the appropriate deployment loops to deploy the air bags. The SDM records the SIR system status when a deployment occurs and turns the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is turned ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will command the AIR BAG indicator ON. In the event that Ignition 1 voltage is lost during a collision, the SDM maintains a 23-volt loop reserve (23 VLR) for deployment of the air bags. It is important to note, when disabling the SIR system for servicing or rescue operations to allow the 23 VLR to dissipate, which could take up to 1 minute. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5554 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer, then roll back the carpet. 4. Remove the connector position assurance (CPA) from the inflatable restraint sensing and diagnostic module (SDM) wiring harness connector. 5. Disconnect the SDM wiring harness connector from the SDM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5555 6. Remove the SDM mounting fasteners (2). 7. Remove the SDM (1) from the floor pan (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the SDM (1) horizontally to the floor pan (3). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: If the old mounting fasteners are damaged, refer to the additional repair procedures at the end of this step. Tighten Tighten the fasteners to 14 N.m (124 lb in). IMPORTANT: The following repair procedures should only be used in the event that the inflatable restraint sensing and diagnostic module (SDM) studs and/or fasteners are damaged to the extent that the SDM can no longer be properly mounted. First Repair 4.1. Discard the old fastener. 4.2. Use a new fastener GM P/N 10156138. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 14 N.m (124 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 5556 Second Repair 4.1. Discard the old fastener. 4.2. Use a larger fastener GM P/N 10267482 with washer GM P/N 11500305. 4.3. Install the SDM mounting fasteners (1). Tighten Tighten the fasteners to 15 N.m (11 lb ft). 5. Install the SDM wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. 10. If you replaced the SDM, perform the following procedure in order to update the BCM with the new SDM part number: 10.1. Install a scan tool. IMPORTANT: The AIR BAG indicator may remain ON after the SDM is replaced. After programming the SDM part number into the BCM, cycle the ignition switch OFF and ON. This turns OFF the AIR BAG indicator and clears the DTC. 10.2. Select the Special Functions option from the SIR Menu and press enter. 10.3. Select the Setup SDM Part Number in BCM option and press enter. 10.4. Follow the procedure on the scan tool display. 10.5. Cycle the ignition switch OFF and ON. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5562 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5563 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5564 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5565 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5566 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5567 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5568 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5569 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5570 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5571 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5572 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5573 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5574 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5575 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5576 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5577 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5578 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5579 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5580 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5581 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5582 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5583 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5584 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5585 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5586 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 5587 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. When removing the center child tether anchor, or the vehicle is equipped with OnStar, and or digital radio perform the following step: 1.1. Remove the rear window trim panel from the rear shelf. 1.2. Remove the tether anchor bolt (3). Digital radio bracket shown, Global Position System (GPS) bracket similar. 1.3. Remove the for the GSP bracket, and or the digital radio bracket (2) from the tether anchor (1). 1.4. Remove the tether anchor (1) from the rear shelf (5). 2. When removing the outer child tether anchor, or the vehicle is not equipped with OnStar, and or digital radio perform the following steps: 2.1. Remove the tether anchor bezel from the rear window shelf trim. 2.2. Remove the bolt from the tether anchor. 2.3. Remove the tether anchor from the rear shelf. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair > Page 5592 1. When installing the outer child tether anchor, or the vehicle is not equipped with OnStar, and or digital radio perform the following steps: 1.1. Position the tether anchor tab to the alignment hole in the rear shelf. 1.2. Install the bolt to the child tether anchor. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT use power tools to tighten the child tether anchor bolts. Tighten Tighten the bolt to 28 N.m (21 lb ft). 1.3. Install tether anchor bezel to the rear window trim shelf. Press into place until fully engaged. 2. When installing the center child tether anchor, or the vehicle is equipped with OnStar, and or Digital radio perform the following step: 2.1. Position the tab on the tether anchor (1) to the alignment hole in the rear shelf (5). Digital radio bracket shown, GPS bracket similar. 2.2. Align the GPS sensor bracket, and or the digital radio bracket (2) to the tether anchor (1). 2.3. Install the bolt (3) for the child tether anchor (1). IMPORTANT: - The digital radio bracket, and or the GPS sensor bracket use the same fastener as the child tether anchor. Check the alignment of the tether anchor, and the bracket to the rear shelf prior to install the fastener. - DO NOT use power tools to tighten the child tether anchor bolts. Tighten Tighten the bolt to 28 N.m (21 lb ft). 2.4. Install the trim panel for the rear window shelf. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance Technical Service Bulletin # 04056 Date: 040823 Recall - Passenger Rear Seat Belt Anchor Non-Compliance F/CMVSS Noncompliance - Passenger - Side Rear Safety Belt Anchorage Compliance # 04056 (Aug 23, 2004) 04056 - Passenger Side Rear Safety Belt Anchorage Compliance 2004 Chevrolet Cavalier 2004 Pontiac Sunfire Condition General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat bolt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries. Correction Dealers are to inspect the safety belt anchorage, and if necessary, install a new nut and bolt. Vehicles Involved Involved are certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5601 Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin.)] Dealer Recall Responsibility - For US The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - ALL Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5602 All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Service Procedure The following service procedure provides instructions for inspecting the size of the weld nut and bolt that attaches the RIGHT rear shoulder belt retractor to the rear panel located between the rear seat back and the back glass. Instructions are also included for replacing the weld nut and bolt if the results of the inspection indicate that replacement is required. Inspection There are two ways to determine if the weld nut and bolt on the RIGHT side are correct. One way is to measure the outside diameter of the weld nut and compare it to the one used on the LEFT side, the other way is to compare the diameter of the bolt hole in the RIGHT weld nut to the hole found in the LEFT side weld nut. 1. Open the rear (trunk) compartment lid. 2. From inside the trunk, reposition the trim and locate the weld nut (1) that attaches the RIGHT rear shoulder belt retractor to the rear panel. 3. Reposition the trim on the opposite side and locate the weld nut that attaches the LEFT rear shoulder belt retractor to the rear panel. 4. Measure and compare the outside diameter of the RIGHT and LEFT weld nuts or, measure and compare the diameter of the bolt holes to each other. ^ If the RIGHT side (diameter or hole) is about 2 mm (1/16 in) SMALLER than the left side (diameter or hole), the RIGHT side weld nut and bolt must be replaced. Proceed to the section titled "Weld Nut and Bolt Replacement" ^ If the RIGHT side (diameter or hole) is the SAME size as the left side (diameter or hole), NO repair is required. Reposition the trim and close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5603 Weld Nut and Bolt Replacement This replacement procedure should only be performed is the results of the inspection procedure indicate that the replacement of the weld nut and bolt is required. Perform this procedure only if the diameter is 2 mm (1/16 in) smaller on the RIGHT side. Two-Door Coupe Model 1. Release both rear seat backs by pulling on the straps. 2. From inside the vehicle, release the center seat belt retractor latch plate (5) from the seat belt buckle. 3. Remove the rear seat cushion. 4. Remove the 2 nuts and 2 bolts attaching the rear seat backs and mounting bracket to the vehicle, and remove the seat back and bracket assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5604 5. Unsnap the driver and passenger front shoulder belt bolt covers (5) and remove the bolts (1). 6. Remove both coat hooks and attaching screws. 7. Loosen the rear of both door opening carpet retainers (sill plates). 8. Remove the rear push-in retainer (5) from the quarter panel extension (4). Important It is not necessary to remove the front seat belt webbing material from the rear quarter trim panel in the next step. 9. Remove the rear quarter panel by pulling firmly and evenly to disengage the retainers. Once the retainers are released, reposition the panel as necessary to remove the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5605 10. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat back retractor. 11. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. 12. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 13. Lift up and reposition the right seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5606 14. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 15. Position the right seat belt retractor back to the original mounting location. 16. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and the hole in the shelf panel. 17. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 18. Route the seat belt webbing material through the slots and install the rear shelf trim panel. 19. Install the bezels for the child tether anchors and the center seat belt retractor. 20. Install the rear quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 21. Install the rear push-in retainer in the quarter panel extension. 22. Press both carpet retainers into position. 23. Install the coat hooks and attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 24. Install the driver and passenger front shoulder belt bolts to the pillars. Tighten Tighten to 41 Nm (30 lb ft). 25. Install the shoulder belt bolt covers and press firmly until fully seated. 26. Install the rear seat back and mounting bracket assembly to the vehicle and install the nuts and bolts. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5607 Tighten the bolts to 25 Nm (18 lb ft). 27. Remove the rear seat cushion retainers from the brackets on the floor and install them to the frame on the bottom of the seat cushion as shown (3). 28. Install the rear seat cushion to the vehicle and press firmly until the retainers are fully seated. 29. Connect the center seat belt retractor latch plate to the seat belt buckle. 30. Close the rear compartment lid. Four Door Sedan Model 1. From the rear seat, release the center seat belt retractor latch plate (5) from the seat belt buckle. 2. From the trunk, release both rear seat backs by pulling on the straps and allowing the seat backs to fold forward and lay flat. 3. From the rear seat remove the rear quarter upper trim (1) and insulator on both sides of the vehicle by pulling firmly and evenly to disengage the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5608 retainers securing the panel. 4. Remove the push-in retainer (1) from the lower quarter trim panel (2) on both sides of the vehicle and pull firmly and evenly to disengage the retainers securing the trim panel. 5. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat belt retractor. 6. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5609 7. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 8. Lift up and reposition the right seat belt retractor. 9. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 10. Position the right seat belt retractor back to the original mounting location. 11. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and hole in the shelf panel. 12. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 13. Route the seat bolt webbing material through the slots and install the rear shelf trim panel. 14. Install the bezels for the child tether anchors and the center seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5610 15. Position the lower quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 16. Install the push-in retainer in each lower quarter trim panel. 17. Install the rear quarter upper trim and insulators on both sides of the vehicle and press firmly and evenly to engage the retainers. 18. Return both rear seat backs to the upright and locked position. 19. Reconnect the center seat belt retractor latch plate to the seat belt buckle. 20. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5611 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5612 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Component Information > Specifications Axle Nut: Specifications Drive Axle Nut ...................................................................................................................................... .................................................. 200 N.m (148 lb ft) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance Technical Service Bulletin # 04056 Date: 040823 Recall - Passenger Rear Seat Belt Anchor Non-Compliance F/CMVSS Noncompliance - Passenger - Side Rear Safety Belt Anchorage Compliance # 04056 (Aug 23, 2004) 04056 - Passenger Side Rear Safety Belt Anchorage Compliance 2004 Chevrolet Cavalier 2004 Pontiac Sunfire Condition General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat bolt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries. Correction Dealers are to inspect the safety belt anchorage, and if necessary, install a new nut and bolt. Vehicles Involved Involved are certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5624 Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin.)] Dealer Recall Responsibility - For US The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - ALL Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5625 All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Service Procedure The following service procedure provides instructions for inspecting the size of the weld nut and bolt that attaches the RIGHT rear shoulder belt retractor to the rear panel located between the rear seat back and the back glass. Instructions are also included for replacing the weld nut and bolt if the results of the inspection indicate that replacement is required. Inspection There are two ways to determine if the weld nut and bolt on the RIGHT side are correct. One way is to measure the outside diameter of the weld nut and compare it to the one used on the LEFT side, the other way is to compare the diameter of the bolt hole in the RIGHT weld nut to the hole found in the LEFT side weld nut. 1. Open the rear (trunk) compartment lid. 2. From inside the trunk, reposition the trim and locate the weld nut (1) that attaches the RIGHT rear shoulder belt retractor to the rear panel. 3. Reposition the trim on the opposite side and locate the weld nut that attaches the LEFT rear shoulder belt retractor to the rear panel. 4. Measure and compare the outside diameter of the RIGHT and LEFT weld nuts or, measure and compare the diameter of the bolt holes to each other. ^ If the RIGHT side (diameter or hole) is about 2 mm (1/16 in) SMALLER than the left side (diameter or hole), the RIGHT side weld nut and bolt must be replaced. Proceed to the section titled "Weld Nut and Bolt Replacement" ^ If the RIGHT side (diameter or hole) is the SAME size as the left side (diameter or hole), NO repair is required. Reposition the trim and close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5626 Weld Nut and Bolt Replacement This replacement procedure should only be performed is the results of the inspection procedure indicate that the replacement of the weld nut and bolt is required. Perform this procedure only if the diameter is 2 mm (1/16 in) smaller on the RIGHT side. Two-Door Coupe Model 1. Release both rear seat backs by pulling on the straps. 2. From inside the vehicle, release the center seat belt retractor latch plate (5) from the seat belt buckle. 3. Remove the rear seat cushion. 4. Remove the 2 nuts and 2 bolts attaching the rear seat backs and mounting bracket to the vehicle, and remove the seat back and bracket assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5627 5. Unsnap the driver and passenger front shoulder belt bolt covers (5) and remove the bolts (1). 6. Remove both coat hooks and attaching screws. 7. Loosen the rear of both door opening carpet retainers (sill plates). 8. Remove the rear push-in retainer (5) from the quarter panel extension (4). Important It is not necessary to remove the front seat belt webbing material from the rear quarter trim panel in the next step. 9. Remove the rear quarter panel by pulling firmly and evenly to disengage the retainers. Once the retainers are released, reposition the panel as necessary to remove the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5628 10. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat back retractor. 11. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. 12. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 13. Lift up and reposition the right seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5629 14. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 15. Position the right seat belt retractor back to the original mounting location. 16. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and the hole in the shelf panel. 17. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 18. Route the seat belt webbing material through the slots and install the rear shelf trim panel. 19. Install the bezels for the child tether anchors and the center seat belt retractor. 20. Install the rear quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 21. Install the rear push-in retainer in the quarter panel extension. 22. Press both carpet retainers into position. 23. Install the coat hooks and attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 24. Install the driver and passenger front shoulder belt bolts to the pillars. Tighten Tighten to 41 Nm (30 lb ft). 25. Install the shoulder belt bolt covers and press firmly until fully seated. 26. Install the rear seat back and mounting bracket assembly to the vehicle and install the nuts and bolts. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5630 Tighten the bolts to 25 Nm (18 lb ft). 27. Remove the rear seat cushion retainers from the brackets on the floor and install them to the frame on the bottom of the seat cushion as shown (3). 28. Install the rear seat cushion to the vehicle and press firmly until the retainers are fully seated. 29. Connect the center seat belt retractor latch plate to the seat belt buckle. 30. Close the rear compartment lid. Four Door Sedan Model 1. From the rear seat, release the center seat belt retractor latch plate (5) from the seat belt buckle. 2. From the trunk, release both rear seat backs by pulling on the straps and allowing the seat backs to fold forward and lay flat. 3. From the rear seat remove the rear quarter upper trim (1) and insulator on both sides of the vehicle by pulling firmly and evenly to disengage the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5631 retainers securing the panel. 4. Remove the push-in retainer (1) from the lower quarter trim panel (2) on both sides of the vehicle and pull firmly and evenly to disengage the retainers securing the trim panel. 5. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat belt retractor. 6. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5632 7. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 8. Lift up and reposition the right seat belt retractor. 9. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 10. Position the right seat belt retractor back to the original mounting location. 11. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and hole in the shelf panel. 12. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 13. Route the seat bolt webbing material through the slots and install the rear shelf trim panel. 14. Install the bezels for the child tether anchors and the center seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5633 15. Position the lower quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 16. Install the push-in retainer in each lower quarter trim panel. 17. Install the rear quarter upper trim and insulators on both sides of the vehicle and press firmly and evenly to engage the retainers. 18. Return both rear seat backs to the upright and locked position. 19. Reconnect the center seat belt retractor latch plate to the seat belt buckle. 20. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5634 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-002A > Apr > 05 > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5635 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance Technical Service Bulletin # 04056 Date: 040823 Recall - Passenger Rear Seat Belt Anchor Non-Compliance F/CMVSS Noncompliance - Passenger - Side Rear Safety Belt Anchorage Compliance # 04056 (Aug 23, 2004) 04056 - Passenger Side Rear Safety Belt Anchorage Compliance 2004 Chevrolet Cavalier 2004 Pontiac Sunfire Condition General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat bolt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries. Correction Dealers are to inspect the safety belt anchorage, and if necessary, install a new nut and bolt. Vehicles Involved Involved are certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5646 Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin.)] Dealer Recall Responsibility - For US The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - ALL Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5647 All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Service Procedure The following service procedure provides instructions for inspecting the size of the weld nut and bolt that attaches the RIGHT rear shoulder belt retractor to the rear panel located between the rear seat back and the back glass. Instructions are also included for replacing the weld nut and bolt if the results of the inspection indicate that replacement is required. Inspection There are two ways to determine if the weld nut and bolt on the RIGHT side are correct. One way is to measure the outside diameter of the weld nut and compare it to the one used on the LEFT side, the other way is to compare the diameter of the bolt hole in the RIGHT weld nut to the hole found in the LEFT side weld nut. 1. Open the rear (trunk) compartment lid. 2. From inside the trunk, reposition the trim and locate the weld nut (1) that attaches the RIGHT rear shoulder belt retractor to the rear panel. 3. Reposition the trim on the opposite side and locate the weld nut that attaches the LEFT rear shoulder belt retractor to the rear panel. 4. Measure and compare the outside diameter of the RIGHT and LEFT weld nuts or, measure and compare the diameter of the bolt holes to each other. ^ If the RIGHT side (diameter or hole) is about 2 mm (1/16 in) SMALLER than the left side (diameter or hole), the RIGHT side weld nut and bolt must be replaced. Proceed to the section titled "Weld Nut and Bolt Replacement" ^ If the RIGHT side (diameter or hole) is the SAME size as the left side (diameter or hole), NO repair is required. Reposition the trim and close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5648 Weld Nut and Bolt Replacement This replacement procedure should only be performed is the results of the inspection procedure indicate that the replacement of the weld nut and bolt is required. Perform this procedure only if the diameter is 2 mm (1/16 in) smaller on the RIGHT side. Two-Door Coupe Model 1. Release both rear seat backs by pulling on the straps. 2. From inside the vehicle, release the center seat belt retractor latch plate (5) from the seat belt buckle. 3. Remove the rear seat cushion. 4. Remove the 2 nuts and 2 bolts attaching the rear seat backs and mounting bracket to the vehicle, and remove the seat back and bracket assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5649 5. Unsnap the driver and passenger front shoulder belt bolt covers (5) and remove the bolts (1). 6. Remove both coat hooks and attaching screws. 7. Loosen the rear of both door opening carpet retainers (sill plates). 8. Remove the rear push-in retainer (5) from the quarter panel extension (4). Important It is not necessary to remove the front seat belt webbing material from the rear quarter trim panel in the next step. 9. Remove the rear quarter panel by pulling firmly and evenly to disengage the retainers. Once the retainers are released, reposition the panel as necessary to remove the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5650 10. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat back retractor. 11. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. 12. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 13. Lift up and reposition the right seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5651 14. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 15. Position the right seat belt retractor back to the original mounting location. 16. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and the hole in the shelf panel. 17. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 18. Route the seat belt webbing material through the slots and install the rear shelf trim panel. 19. Install the bezels for the child tether anchors and the center seat belt retractor. 20. Install the rear quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 21. Install the rear push-in retainer in the quarter panel extension. 22. Press both carpet retainers into position. 23. Install the coat hooks and attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 24. Install the driver and passenger front shoulder belt bolts to the pillars. Tighten Tighten to 41 Nm (30 lb ft). 25. Install the shoulder belt bolt covers and press firmly until fully seated. 26. Install the rear seat back and mounting bracket assembly to the vehicle and install the nuts and bolts. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5652 Tighten the bolts to 25 Nm (18 lb ft). 27. Remove the rear seat cushion retainers from the brackets on the floor and install them to the frame on the bottom of the seat cushion as shown (3). 28. Install the rear seat cushion to the vehicle and press firmly until the retainers are fully seated. 29. Connect the center seat belt retractor latch plate to the seat belt buckle. 30. Close the rear compartment lid. Four Door Sedan Model 1. From the rear seat, release the center seat belt retractor latch plate (5) from the seat belt buckle. 2. From the trunk, release both rear seat backs by pulling on the straps and allowing the seat backs to fold forward and lay flat. 3. From the rear seat remove the rear quarter upper trim (1) and insulator on both sides of the vehicle by pulling firmly and evenly to disengage the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5653 retainers securing the panel. 4. Remove the push-in retainer (1) from the lower quarter trim panel (2) on both sides of the vehicle and pull firmly and evenly to disengage the retainers securing the trim panel. 5. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat belt retractor. 6. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5654 7. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 8. Lift up and reposition the right seat belt retractor. 9. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 10. Position the right seat belt retractor back to the original mounting location. 11. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and hole in the shelf panel. 12. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 13. Route the seat bolt webbing material through the slots and install the rear shelf trim panel. 14. Install the bezels for the child tether anchors and the center seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5655 15. Position the lower quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 16. Install the push-in retainer in each lower quarter trim panel. 17. Install the rear quarter upper trim and insulators on both sides of the vehicle and press firmly and evenly to engage the retainers. 18. Return both rear seat backs to the upright and locked position. 19. Reconnect the center seat belt retractor latch plate to the seat belt buckle. 20. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5656 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5657 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance Technical Service Bulletin # 04056 Date: 040823 Recall - Passenger Rear Seat Belt Anchor Non-Compliance F/CMVSS Noncompliance - Passenger - Side Rear Safety Belt Anchorage Compliance # 04056 (Aug 23, 2004) 04056 - Passenger Side Rear Safety Belt Anchorage Compliance 2004 Chevrolet Cavalier 2004 Pontiac Sunfire Condition General Motors has decided that certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles fail to conform to Federal/Canada Motor Vehicle Safety Standard 209, Seat Belt Assemblies, and Standard 210, Seat Belt Assembly Anchorages. On some of these vehicles, the passenger side rear safety belt may have been installed with an incorrect nut and bolt. In a severe crash, the upper seat bolt anchorage may separate. The effectiveness of the seat belt could then be reduced and the occupant could receive greater injuries. Correction Dealers are to inspect the safety belt anchorage, and if necessary, install a new nut and bolt. Vehicles Involved Involved are certain 2004 model year Chevrolet Cavalier and Pontiac Sunfire vehicles built within the VIN breakpoints shown. Important Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld. For Canada For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a Campaign Initiation Detail Report. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5663 Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information Customer Notification - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin.)] Dealer Recall Responsibility - For US The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. This bulletin is notice to you that the new motor vehicles included in this recall may not comply with the standard identified above. Under Title 49, Section 30112 of the United States Code, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety Standard. As a consequence, if you sell any of these motor vehicles without first performing the recall correction, your dealership may be subject to a civil penalty for each such sale. Dealer Recall Responsibility - ALL Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5664 All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter shown in this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Service Procedure The following service procedure provides instructions for inspecting the size of the weld nut and bolt that attaches the RIGHT rear shoulder belt retractor to the rear panel located between the rear seat back and the back glass. Instructions are also included for replacing the weld nut and bolt if the results of the inspection indicate that replacement is required. Inspection There are two ways to determine if the weld nut and bolt on the RIGHT side are correct. One way is to measure the outside diameter of the weld nut and compare it to the one used on the LEFT side, the other way is to compare the diameter of the bolt hole in the RIGHT weld nut to the hole found in the LEFT side weld nut. 1. Open the rear (trunk) compartment lid. 2. From inside the trunk, reposition the trim and locate the weld nut (1) that attaches the RIGHT rear shoulder belt retractor to the rear panel. 3. Reposition the trim on the opposite side and locate the weld nut that attaches the LEFT rear shoulder belt retractor to the rear panel. 4. Measure and compare the outside diameter of the RIGHT and LEFT weld nuts or, measure and compare the diameter of the bolt holes to each other. ^ If the RIGHT side (diameter or hole) is about 2 mm (1/16 in) SMALLER than the left side (diameter or hole), the RIGHT side weld nut and bolt must be replaced. Proceed to the section titled "Weld Nut and Bolt Replacement" ^ If the RIGHT side (diameter or hole) is the SAME size as the left side (diameter or hole), NO repair is required. Reposition the trim and close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5665 Weld Nut and Bolt Replacement This replacement procedure should only be performed is the results of the inspection procedure indicate that the replacement of the weld nut and bolt is required. Perform this procedure only if the diameter is 2 mm (1/16 in) smaller on the RIGHT side. Two-Door Coupe Model 1. Release both rear seat backs by pulling on the straps. 2. From inside the vehicle, release the center seat belt retractor latch plate (5) from the seat belt buckle. 3. Remove the rear seat cushion. 4. Remove the 2 nuts and 2 bolts attaching the rear seat backs and mounting bracket to the vehicle, and remove the seat back and bracket assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5666 5. Unsnap the driver and passenger front shoulder belt bolt covers (5) and remove the bolts (1). 6. Remove both coat hooks and attaching screws. 7. Loosen the rear of both door opening carpet retainers (sill plates). 8. Remove the rear push-in retainer (5) from the quarter panel extension (4). Important It is not necessary to remove the front seat belt webbing material from the rear quarter trim panel in the next step. 9. Remove the rear quarter panel by pulling firmly and evenly to disengage the retainers. Once the retainers are released, reposition the panel as necessary to remove the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5667 10. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat back retractor. 11. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. 12. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 13. Lift up and reposition the right seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5668 14. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 15. Position the right seat belt retractor back to the original mounting location. 16. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and the hole in the shelf panel. 17. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 18. Route the seat belt webbing material through the slots and install the rear shelf trim panel. 19. Install the bezels for the child tether anchors and the center seat belt retractor. 20. Install the rear quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 21. Install the rear push-in retainer in the quarter panel extension. 22. Press both carpet retainers into position. 23. Install the coat hooks and attaching screws. Tighten Tighten the screws to 2 Nm (18 lb in). 24. Install the driver and passenger front shoulder belt bolts to the pillars. Tighten Tighten to 41 Nm (30 lb ft). 25. Install the shoulder belt bolt covers and press firmly until fully seated. 26. Install the rear seat back and mounting bracket assembly to the vehicle and install the nuts and bolts. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5669 Tighten the bolts to 25 Nm (18 lb ft). 27. Remove the rear seat cushion retainers from the brackets on the floor and install them to the frame on the bottom of the seat cushion as shown (3). 28. Install the rear seat cushion to the vehicle and press firmly until the retainers are fully seated. 29. Connect the center seat belt retractor latch plate to the seat belt buckle. 30. Close the rear compartment lid. Four Door Sedan Model 1. From the rear seat, release the center seat belt retractor latch plate (5) from the seat belt buckle. 2. From the trunk, release both rear seat backs by pulling on the straps and allowing the seat backs to fold forward and lay flat. 3. From the rear seat remove the rear quarter upper trim (1) and insulator on both sides of the vehicle by pulling firmly and evenly to disengage the Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5670 retainers securing the panel. 4. Remove the push-in retainer (1) from the lower quarter trim panel (2) on both sides of the vehicle and pull firmly and evenly to disengage the retainers securing the trim panel. 5. Lift up, unsnap, and remove the bezels (2) for the child tether anchors and the bezel (1) for the center seat belt retractor. 6. Remove the rear shelf trim panel (3) and route the seat belt webbing material through the slots. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5671 7. Remove the bolt (1) attaching the right side retractor to the rear shelf panel. 8. Lift up and reposition the right seat belt retractor. 9. From inside the trunk, remove the 8 mm weld nut (1) from the underside of the shelf panel. 10. Position the right seat belt retractor back to the original mounting location. 11. Apply threadlocker to the threads of the new bolt and insert the bolt through the seat belt retractor and hole in the shelf panel. 12. From inside the rear compartment, install the NEW nut on the bolt. Tighten Tighten the bolt to 28 Nm (21 lb ft). 13. Route the seat bolt webbing material through the slots and install the rear shelf trim panel. 14. Install the bezels for the child tether anchors and the center seat belt retractor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5672 15. Position the lower quarter trim panels on both sides of the vehicle. Align the retainers and press firmly and evenly to engage. 16. Install the push-in retainer in each lower quarter trim panel. 17. Install the rear quarter upper trim and insulators on both sides of the vehicle and press firmly and evenly to engage the retainers. 18. Return both rear seat backs to the upright and locked position. 19. Reconnect the center seat belt retractor latch plate to the seat belt buckle. 20. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5673 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 00-08-46-003B > Feb > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 04056 > Aug > 04 > Recall - Passenger Rear Seat Belt Anchor Non-Compliance > Page 5674 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 5683 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 5689 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 5690 Seat Belt Buckle: Service Precautions CAUTION: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Left Front REMOVAL PROCEDURE 1. Disable the SIR system, if equipped with Side Impact Air Bag (SIAB). Refer to SIR Disabling and Enabling Zone 7 or SIR Disabling and Enabling Zone 9 in Restraints. CAUTION: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 2. Remove the front bucket seat. 3. Disconnect the seat belt buckle electrical connector. 4. Remove the seat belt buckle bolt (1). 5. Remove the seat belt buckle from the seat. INSTALLATION PROCEDURE 1. Position the seat belt buckle to the seat. 2. Install the seat belt buckle bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 34 N.m (25 lb ft). 3. Connect the seat belt buckle electrical connector. 4. Install the front bucket seat. 5. Enable the SIR system, if equipped with SIAB. Refer to SIR Disabling and Enabling Zone 7 or SIR Disabling and Enabling Zone 9 in Restraints. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 5693 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Right Front REMOVAL PROCEDURE 1. Position the right front bucket seat to the most forward position. 2. Remove the seat belt buckle bolt plug (2). 3. Remove the seat belt buckle bolt (3). 4. Remove the seat belt buckle from the floor pan tunnel. INSTALLATION PROCEDURE 1. Position the seat belt buckle to the floor pan tunnel 2. Install the seat belt buckle bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 48 N.m (35 lb ft). 3. Install the seat belt buckle bolt plug. 4. Reposition the right front seat to the original position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 5694 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the nut from the rear seat belt buckles. 3. Remove the seat belt buckles from the floor pan studs. INSTALLATION PROCEDURE 1. Position the seat belt buckles to the floor pan studs. 2. Install the rear seat belt buckle nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 50 N.m (37 lb ft). 3. Install the rear seat cushion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5698 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair Seat Belt Guide Track: Service and Repair GUIDE REPLACEMENT - REAR SEAT SHOULDER BELT REMOVAL PROCEDURE 1. Position the rear seat back (3) to remove the child comfort guide (2). 2. Release the push pin retainer (1) from the rear seat back (3). 3. Remove the child comfort guide (2) from the rear seat back (3). 4. Remove the shoulder belt from the comfort guide, if necessary. INSTALLATION PROCEDURE 1. Install the shoulder belt to the child comfort guide (2). 2. Install the comfort guide to the rear seat back (3). 3. Install the push pin retainer (1) to the rear seat back (3). 4. Reposition the rear seat back (3) to the original position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair SEAT BELT HEIGHT ADJUSTER REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the center pillar upper trim panel. 2. Remove the front seat shoulder belt guide track cover. 3. Remove the front seat shoulder belt guide track bolts. 4. Remove the front seat shoulder belt guide track. INSTALLATION PROCEDURE 1. Install the front seat shoulder belt guide track. 2. Install the front seat shoulder belt guide track bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 28 N.m (21 lb ft). 3. Install the front seat shoulder belt guide track cover. 4. Install the center pillar upper trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Front (Sedan) REMOVAL PROCEDURE 1. Remove the plug for seat belt anchor bolt. 2. Remove the seat belt anchor bolt. 3. Lift up on the bottom edge of the shoulder belt guide cover. 4. Remove the shoulder belt guide bolt. 5. Remove the carpet retainer. 6. Remove the seat belt retractor bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5713 7. Pull upward on the seat belt retractor. This will disengage the retractor from the T-slot in the center pillar. INSTALLATION PROCEDURE 1. Insert the top of the seat belt retractor into the T-slot. Push down the top of the retractor to engage the retractor with the T-slot in the center pillar. IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 2. Install the seat belt retractor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 48 N.m (35 lb ft). 3. Install the left carpet retainer 4. Install the shoulder belt guide bolt. Tighten Tighten the bolt to 41 N.m (30 lb ft). 5. Push down on the shoulder belt guide cover until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5714 6. Install the seat belt anchor bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). 7. Install the seat belt sleeve anchor plug. 8. Inspect left front seat belt retractor for proper operation. Refer to Operational and Functional Checks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5715 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Front (Coupe) REMOVAL PROCEDURE 1. Remove the seat belt anchor plug (3). 2. Remove the seat belt anchor bolt (4). 3. Lift up on the bottom edge of the shoulder belt guide cover (5). 4. Remove the shoulder belt guide bolt (1). 5. Remove the rear quarter trim panel. 6. Remove the seat belt intermediate guide rivet. 7. Remove the seat belt retractor bolt (2). 8. Pull upward on the seat belt retractor. This will disengage the retractor from the T-slot in the center pillar. INSTALLATION PROCEDURE IMPORTANT: Remove any twists in the seat belt webbing before final assembly. 1. Insert the top of the seat belt retractor into the T-slot. Push down the top of the retractor to engage the retractor with the T-slot in the center pillar. 2. Install the seat belt retractor bolt (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 48 N.m (35 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5716 3. Install the seat belt intermediate guide rivet. 4. Install the rear quarter trim panel. 5. Install the shoulder belt guide bolt (1). Tighten Tighten the bolt to 41 N.m (30 lb ft). 6. Push down on the shoulder belt guide cover (5) until fully seated. 7. Install the seat belt anchor bolt (4). Tighten Tighten the bolt to 48 N.m (35 lb ft). 8. Install the seat belt anchor bolt plug (3). 9. Inspect the seat belt retractor for proper operation. Refer to Operational and Functional Checks. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5717 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear window panel trim. 2. Remove the rear seat cushion, if necessary. 3. Remove the rear seat belt retractor anchor plate bolt. 4. Remove the retractor anchor plate from the floor. 5. Remove the retractor bolt (1). 6. Remove the retractor from the rear shelf. INSTALLATION PROCEDURE 1. Install the retractor to the rear shelf. 2. Install the retractor bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 28 N.m (21 lb ft). 3. Install the retractor anchor plate to the floor pan. 4. Install the retractor anchor plate bolt. Tighten Tighten the bolt to 48 N.m (35 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5718 5. Install the rear seat cushion, if necessary. 6. Install the rear window panel trim. 7. Check the rear seat retractor belt for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Front (Sedan) > Page 5719 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear window panel trim. 2. Open the rear compartment. 3. Remove the center rear seat belt retractor bolt (3) from the rear compartment. 4. Slide the retractor (1) forward to disengage the locking tab (4) from the retractor bracket (5). 5. From inside the vehicle remove the retractor (1) from the rear shelf (2). INSTALLATION PROCEDURE 1. From inside the vehicle install the rear seat belt retractor assembly (1) to the rear shelf (2). 2. From the rear compartment slide the retractor rearward to engage the locking tab (4) into the retractor bracket (5). 3. Install the rear seat belt retractor bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 28 N.m (21 lb ft). 4. Install the rear window panel trim. 5. Check the rear seat retractor belt for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: Customer Interest Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 05-09-41-002 > Jan > 05 > Restraint System - SIR Lamp ON/DTC B0036 Set Impact Sensor: All Technical Service Bulletins Restraint System - SIR Lamp ON/DTC B0036 Set Bulletin No.: 05-09-41-002 Date: January 28, 2005 INFORMATION Subject: Diagnostic Information for SIR Light Illuminated with DTC B0036 Set Models: 2004-2005 Chevrolet Cavalier 2004-2005 Pontiac Sunfire When diagnosing a concern for Supplemental Inflatable Restraint (SIR) light illuminated and Diagnostic Trouble Code (DTC) B0036 set, verify the connection at the Sensing and Diagnostic module (SDM) for the forward auxiliary discriminating Electronic Front-End sensor (EFS). Disconnect this connector and reconnect making sure that you have a proper fit. Clear this DTC and retest prior to replacing the forward EFS. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel Discriminating Sensor And Steering Wheel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 5736 Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Discriminating Sensor and Steering Wheel > Page 5737 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5738 Impact Sensor: Diagrams Inflatable Restraint Front End Discriminating Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5739 Inflatable Restraint Side Impact Sensor - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5740 Inflatable Restraint Side Impact Sensor - Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5741 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 5742 Impact Sensor: Description and Operation INFLATABLE RESTRAINT FRONT END SENSOR The front end sensor, also known as the electronic frontal sensor (EFS), is equipped on some vehicles to supplement SIR system performance. The EFS is an electro-mechanical sensor and is not part of the deployment loops, but instead provides an input to the SDM. The SDM uses the input from the EFS to assist in determining the severity of a frontal collision further supporting air bag deployment. If the SDM determines a deployment is warranted, the SDM will cause current to flow through the deployment loops deploying the frontal air bags. INFLATABLE RESTRAINT SIDE IMPACT SENSORS (SIS) The side impact sensors (SIS) contain a sensing device which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant side inflator module deployment. Each SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the side air bags. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the pushpin retainers from the hood close out panel. 3. Remove the hood close out panel from the vehicle. 4. Remove the connector position assurance (CPA) from the wiring harness connector. 5. Disconnect the wiring harness connector from the sensor (1). 6. Remove the mounting bolts (2) from the sensor (1). 7. Remove the sensor (1) from the hood latch support bracket (3). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5745 1. Install the sensor (1) to the hood latch support bracket (3). 2. Install the mounting bolts (2) to the sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Connect the wiring harness connector to the sensor (1). 4. Install the CPA to the wiring harness connector. 5. Install the hood close out panel to the vehicle. 6. Install the pushpin retainers to the hood close out panel. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5746 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Sedan) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the center pillar upper trim. 3. Loosen the bolts (2) on the inflatable restraint side impact sensor. 4. Remove the inflatable restraint side impact sensor from the center pillar (1). 5. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 6. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5747 1. Connect the side impact sensor connector (4). 2. Install the CPA (3) to the side impact sensor connector (4). 3. Remove any dirt, grease, or other impurities from the mounting surface. 4. Install the side impact sensor to the center pillar (1). 5. Align the locating pin on the sensor to the opening in the center pillar (1). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar upper trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5748 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Coupe) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9 or to SIR Disabling and Enabling Zone 7. CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. 2. Remove the door trim panel. 3. Remove enough of the water deflector to access the side impact sensor (1). 4. Loosen the bolts (2) on the inflatable restraint side impact sensor (1). 5. Remove the inflatable restraint side impact sensor (1) from the door (4). 6. Remove the connector position assurance (CPA) (3) from the side impact sensor connector (4). 7. Disconnect the side impact sensor connector (4). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 5749 2. Connect the side impact sensor connector (4). 3. Install the CPA (3) to the side impact sensor connector (4). 4. Install the side impact sensor (1) to the door (4). 5. Align the locating pin on the sensor (1) to the opening in the door (4). Begin tightening the side impact sensor bolts (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the water deflector to the door. 7. Install the door trim panel. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9 , or SIR Disabling and Enabling Zone 7. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 5753 Seat Belt Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams Accessory Delay Module: Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 5762 Retained Accessory Power (RAP) Diagram 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 5763 Accessory Delay Module: Description and Operation SERIAL DATA CONTROLLED RETAINED ACCESSORY POWER, RAP Retained accessory power, RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The Audio system on this vehicle is the only device that is controlled by RAP. SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER, RAP The Radio receives a RAP message from the Body Control Module, BCM over the serial data circuits. The BCM module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM module then sends a message to the Radio telling it that it is in RAP power mode. RAP will end when one of the following conditions are met: The BCM module receives an input from the drivers door jam switch. - The BCM module receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM module detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM module then sends a serial data message to the Radio ending the RAP function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5766 Steps 3-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5767 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Retained Accessory Power (RAP) - Inoperative RETAINED ACCESSORY POWER (RAP) INOPERATIVE DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module , BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5768 Steps 1-5 Retained Accessory Power (RAP) - On After Timeout RETAINED ACCESSORY POWER (RAP) ON AFTER TIMEOUT DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module, BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5769 Steps 1-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5770 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Use the Scan Tool Data Display Values and Definitions Information in order to assist in diagnosing vehicle malfunctions. Compare the vehicles actual scan tool data with the typical data display value table information. Use the data information in order to aid in understanding the nature of the problem when the vehicle does not match with the typical data display values. The scan tool data values were taken from a known good vehicle under the following conditions: - The ignition switch is in the ON position. - The engine is not running. - The vehicle is in PARK. Accessory: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or ACCY position. Battery Voltage: This voltage value refers to the battery system voltage. Driver Door Ajar Sw.: The scan tool displays On/Off. On is displayed when the driver door is open, Off when closed. Ignition 1: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or CRANK position. Key In Ignition: This information refers to whether or not the ignition key is inserted into the ignition switch. The BCM uses this data to perform chime functions. ON is displayed when the key is inserted into the ignition switch. Passenger Door Ajar Sw.: The scan tool displays On/Off. On is displayed when at least one passenger door is open, Off when all passenger doors are closed. Scan Tool Data List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 5785 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 5795 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Page 5796 Antenna, Navigation: Description and Operation CELLULAR AND NAVIGATION ANTENNAS This vehicle will be equipped with either separate cellular and navigation antennas, or a combination cellular and navigation antenna, which brings the functions of both into a single part. The cellular antenna is the component that allows the OnStar(R) system to send and receive data over airwaves by means of cellular technology. This antenna is connected at the base to a coax cable that plugs directly into the VCIM. The navigation antenna is used to collect the constant signals of the orbiting satellites. Within the antenna, is housed a low noise amplifier that allows for a more broad and precise reception of this data. Current GPS location is collected by the module every time a keypress is made. The OnStar(R) Call Center also has the capability of pinging the vehicle during an OnStar(R) call, which commands the module to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged. In the event the VCP loses or is removed from power, this history location is used by the OnStar(R) Call Center as a default. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. This antenna requires a clear and unobstructed path to the satellites in the sky. Window tinting on vehicles may interfere with the GPS sensor functions, depending upon the amount of darkening and/or metallic particles that are embedded in the film of the tinting material. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 5801 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 5806 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE 1. Disconnect the coaxial cable from the mobile communication antenna inner coupling (2). IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the couplings. - The adhesion promoter must be used to obtain maximum adhesion between the new cellular antenna couplings and the glass surface. The couplings and the glass must be kept dry and above 15°C (60°F) during the installation. Allow 6-8 hours at 15°C (60°F) for the adhesive to cure after installation. Otherwise the new couplings may come off. - Do not use any type of glue, adhesive tapes, etc. to reinstall the original couplings. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling (2). NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. INSTALLATION PROCEDURE 1. Clean the inside of the rear window with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply glass adhesion promoter GM P/N 12378555 (Canadian P/N 88901239) to the rear window in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - Mark off or protect areas before applying the adhesion promoter. 1. Remove the protective film from the adhesive backing on the inner antenna coupling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 5809 IMPORTANT: Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. - The RF connections for the inner antenna coupling should run parallel to the defogger gridline. 1. Align the inner antenna coupling to the outer antenna coupling, or to the locating marks on the rear window above the defogger grid line. 2. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the rear window (4). Hold pressure on the inner coupling (2) for 10-30 seconds. 3. Ensure that no gaps occur between the couplings (2,5) and the rear window (4). 4. Connect the coaxial cable to the inner coupling (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 5810 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE 1. Install the inner coupling (2) first if both the inner and the outer coupling (5) are being replaced. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - The adhesion promoter must be used to obtain maximum adhesion between the new mobile antenna couplings and the glass surface. The couplings and the glass must be kept dry and above 15°C (60°F) during the installation. Allow 6-8 hours at 15°C (60°F), for the adhesive to cure after installation. Otherwise the new coupling may come off. - Do not use any type of glue, adhesive tapes, etc. to reinstall the original couplings. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a small wide-bladed plastic tool to cut the double back tape material (1) while lifting up on the outer antenna coupling (5). NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. INSTALLATION PROCEDURE 1. Clean the rear window with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply glass adhesion promoter GM P/N 12378555 (Canadian P/N 88901239) to the rear window in the area where you will install the coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure bonding of the coupling. - Mask off or protect areas before applying the adhesion promoter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 5811 1. Remove the protective film from the adhesive backing on the outer antenna coupling. IMPORTANT: Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. Align the outer antenna coupling to the inner antenna coupling. 2. Press firmly on all 4 corners and the center of the antenna outer coupling (5) in order to ensure proper adhesion to the rear window (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 3. Ensure that no gaps occur between the couplings (2,5) and the back glass (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 5812 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove rear shelf trim panel. 2. Remove the rosebud retainers securing the global position sensor (GPS) antenna wire harness to the rear shelf and the upper rear quarter panel. 3. Disconnect the electrical connection for the GPS antenna wire harness from the headliner wire harness. 4. Remove the child tether attachment bolt (3) form the GPS antenna bracket (2). 5. Lift the GPS antenna bracket (2) at a 45-degree angle to disengage the locating tabs (5) from the slots in the rear shelf (6). 6. Remove the GPS antenna assembly from the rear shelf (6). INSTALLATION PROCEDURE 1. Install the GPS antenna bracket (2) at a 45-degree angle to engage the locating tabs (5) into the slots in the rear shelf (6). IMPORTANT: The GPS antenna bracket and the child tether attachment use the same fastener. Check the alignment of the child tether attachment and the GPS bracket to the rear shelf prior to installing the fastener. 2. Install the child tether attachment bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 28 N.m (20 lb ft). 3. Connect the electrical connection for the GPS antenna wire harness to the headliner wire harness. 4. Install the rosebud retainers securing the GPS antenna wire harness to the rear shelf and the upper rear quarter panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 5813 5. Install the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio COAXIAL CABLE REPLACEMENT - DIGITAL RADIO REMOVAL PROCEDURE 1. Remove the rear window trim panel. 2. Disconnect the coaxial cable connector (4) from the digital radio receiver. 3. Cut off the visible end from the coaxial cable. 4. Lower the headliner enough to access the wire harness. 5. Disconnect the coaxial cable connectors (3) at the antenna base. 6. Cut off the visible end of the coaxial cable. INSTALLATION PROCEDURE 1. Position the replacement coaxial cable (4) along side the old coaxial cable harness. Secure the new coaxial cable to the old coaxial harness every 150 mm (6 in) with electrical tape, nylon straps, or a hot glue gun. 2. Connect the coaxial cable to the pigtail connector (2) at the antenna base. 3. Install the headliner (8) to the original position. 4. Install the coax cable connector (5) to the digital radio receiver. 5. Install the rear window trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 5819 Antenna Cable: Service and Repair Coaxial Cable Replacement COAXIAL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear shelf trim panel if equipped with antenna amplifier. 2. Remove the rear seat cushion. 3. Remove the rear seat back. 4. Remove the right carpet retainers. 5. Remove the center pillar trim panel. 6. Pull back the carpet for access to the wiring harness as required. 7. Disconnect the antenna coaxial cable from the rear of the radio. 8. Cut off the visible end of the coaxial antenna cable (1) from the wiring harness in the instrument panel area. 9. Cut off the visible end of the coaxial antenna cable from the wiring harness in the rear shelf area. INSTALLATION PROCEDURE 1. Install the coaxial antenna cables to the wiring harness. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Secure the cable to the harness at least every 150 mm (6 in). 2. Connect the coaxial antenna cable to the rear of the radio. Install the radio. 3. Reposition the carpet. 4. Install the center pillar trim panel. 5. Install the right carpet retainers. 6. Position the coaxial antenna cable from the body wiring harness to the rear shelf area. 7. Install the rear shelf trim panel if equipped with antenna amplifier. 8. Install the rear seat back. 9. Install the rear seat cushion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REMOVAL PROCEDURE 1. Insert a small flat-bladed tool between the 2 halves of the transmitter case (6,4) at the slot provided near the key ring (5) hole. 2. Twist the tool in order to open the case. 3. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side facing down. Use one 3-volt CR2032 battery or the equivalent. 2. Ensure the transmitter case seal is in the proper position. 3. Align the 2 halves of the transmitter case (6,4). 4. Snap the 2 halves of the transmitter case together. 5. Test the operation of the transmitter. IMPORTANT: Normal battery life is approximately 2 years. Replace the batteries when the range of the transmitter begins to decrease significantly to less than approximately 7 m (23 ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams Passlock(TM) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Page 5829 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation SECURITY INDICATOR The SECURITY indicator on the instrument cluster is controlled by both the VTD system and the CTD system. The SECURITY indicator is an LED on the instrument cluster which illuminates the word THEFT. The SECURITY indicator is controlled by the body control module grounding the security indicator control circuit. - The VTD system commands the instrument cluster to control the indicator only when the ignition switch is ON. The VTD system uses the indicator as a malfunction indicator. - The CTD system commands the instrument cluster to control the indicator only when the ignition switch is OFF. The CTD system uses the indicator to identify system status. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams Cellular Microphone Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Diagrams > Page 5840 Cellular Phone Microphone: Description and Operation ONSTAR(R) MICROPHONE The OnStar(R), or cellular, microphone can be part of the rearview mirror assembly, or on some vehicle lines, can be a separate, stand alone unit. In either case, the microphone is supplied voltage on the cellular microphone signal circuit, while voice data from the user is sent back to the VCIM by means of either a cellular microphone low reference circuit or a drain wire. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5853 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5854 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5855 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5856 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5857 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5858 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5859 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5860 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5861 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5862 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5863 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5864 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5865 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5866 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5867 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5868 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5869 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5870 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5871 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5872 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5873 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5874 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5875 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5876 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5877 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5878 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5879 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5880 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5881 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5882 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5883 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5884 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5885 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5886 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 5892 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 5897 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 5902 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 5903 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 5909 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5918 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5919 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5920 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5921 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5922 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5923 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5924 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5925 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5926 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5927 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5928 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5929 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5930 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5931 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5932 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5933 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5934 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5935 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5936 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5937 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5938 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5939 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5940 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5941 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5942 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 5943 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5948 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5949 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5950 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5951 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5952 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5953 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5954 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5955 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5956 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5957 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5958 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5959 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5960 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5961 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5962 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5963 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5964 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5965 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5966 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5967 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5968 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5969 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5970 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5971 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5972 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5973 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5974 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5975 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5976 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5977 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5978 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5979 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5980 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 5981 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5986 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5987 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5988 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5989 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5990 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5991 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5992 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5993 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5994 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5995 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5996 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 5997 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 6002 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6015 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6020 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6021 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 03-07-29-005B > Jul > 04 > M/T - Clunk/Creak Noise From Front End > Page 6027 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6037 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6038 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6039 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6040 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6041 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6042 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6043 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6044 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6045 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6046 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6047 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6048 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6049 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6050 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6051 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6052 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6053 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6054 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6055 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6056 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6057 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6058 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6059 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6060 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6061 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6062 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6067 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6068 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6069 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6070 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6071 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6072 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6073 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6074 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6075 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6076 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6077 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6078 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6079 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6080 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6081 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6082 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6083 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6084 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6085 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6086 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6087 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6088 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6089 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6090 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6091 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6092 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6093 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6094 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6095 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6096 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6097 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6098 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6099 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6100 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6105 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6106 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6107 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6108 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6109 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6110 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6111 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6112 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6113 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6114 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6115 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6116 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 6121 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 6140 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE 1. Disconnect the coaxial cable from the mobile communication antenna inner coupling (2). IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the couplings. - The adhesion promoter must be used to obtain maximum adhesion between the new cellular antenna couplings and the glass surface. The couplings and the glass must be kept dry and above 15°C (60°F) during the installation. Allow 6-8 hours at 15°C (60°F) for the adhesive to cure after installation. Otherwise the new couplings may come off. - Do not use any type of glue, adhesive tapes, etc. to reinstall the original couplings. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling (2). NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. INSTALLATION PROCEDURE 1. Clean the inside of the rear window with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply glass adhesion promoter GM P/N 12378555 (Canadian P/N 88901239) to the rear window in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - Mark off or protect areas before applying the adhesion promoter. 1. Remove the protective film from the adhesive backing on the inner antenna coupling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 6143 IMPORTANT: Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. - The RF connections for the inner antenna coupling should run parallel to the defogger gridline. 1. Align the inner antenna coupling to the outer antenna coupling, or to the locating marks on the rear window above the defogger grid line. 2. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the rear window (4). Hold pressure on the inner coupling (2) for 10-30 seconds. 3. Ensure that no gaps occur between the couplings (2,5) and the rear window (4). 4. Connect the coaxial cable to the inner coupling (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 6144 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE 1. Install the inner coupling (2) first if both the inner and the outer coupling (5) are being replaced. IMPORTANT: The adhesion promoter must be used to assure adequate bonding of the coupling. - The adhesion promoter must be used to obtain maximum adhesion between the new mobile antenna couplings and the glass surface. The couplings and the glass must be kept dry and above 15°C (60°F) during the installation. Allow 6-8 hours at 15°C (60°F), for the adhesive to cure after installation. Otherwise the new coupling may come off. - Do not use any type of glue, adhesive tapes, etc. to reinstall the original couplings. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Use a small wide-bladed plastic tool to cut the double back tape material (1) while lifting up on the outer antenna coupling (5). NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. INSTALLATION PROCEDURE 1. Clean the rear window with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply glass adhesion promoter GM P/N 12378555 (Canadian P/N 88901239) to the rear window in the area where you will install the coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The adhesion promoter must be used to assure bonding of the coupling. - Mask off or protect areas before applying the adhesion promoter. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 6145 1. Remove the protective film from the adhesive backing on the outer antenna coupling. IMPORTANT: Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. Align the outer antenna coupling to the inner antenna coupling. 2. Press firmly on all 4 corners and the center of the antenna outer coupling (5) in order to ensure proper adhesion to the rear window (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 3. Ensure that no gaps occur between the couplings (2,5) and the back glass (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 6146 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove rear shelf trim panel. 2. Remove the rosebud retainers securing the global position sensor (GPS) antenna wire harness to the rear shelf and the upper rear quarter panel. 3. Disconnect the electrical connection for the GPS antenna wire harness from the headliner wire harness. 4. Remove the child tether attachment bolt (3) form the GPS antenna bracket (2). 5. Lift the GPS antenna bracket (2) at a 45-degree angle to disengage the locating tabs (5) from the slots in the rear shelf (6). 6. Remove the GPS antenna assembly from the rear shelf (6). INSTALLATION PROCEDURE 1. Install the GPS antenna bracket (2) at a 45-degree angle to engage the locating tabs (5) into the slots in the rear shelf (6). IMPORTANT: The GPS antenna bracket and the child tether attachment use the same fastener. Check the alignment of the child tether attachment and the GPS bracket to the rear shelf prior to installing the fastener. 2. Install the child tether attachment bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 28 N.m (20 lb ft). 3. Connect the electrical connection for the GPS antenna wire harness to the headliner wire harness. 4. Install the rosebud retainers securing the GPS antenna wire harness to the rear shelf and the upper rear quarter panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 6147 5. Install the rear shelf trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Disable the SIR. 2. Remove the passenger inflatable restraint module. 3. Remove the I/P carrier bolts on the passenger side. 4. Remove the bolt (1) for the module bracket strap (7). 5. Remove the module bracket strap (7) from the mounting bracket (3). 6. Slide the module (2) upward in the mounting bracket. IMPORTANT: The generation 5 module uses four connector cavities. In addition, the STID and the ESN information on the generation 5 label can not be used to update the customer account information if the module is replaced. Use a scan tool to access this information. 7. Disconnect all the electrical connector (3) from the communication interface module (1). 8. Disconnect all the coaxial cable connectors (4) from the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 6151 9. Pull downward on the back of the I/P compartment to remove the OnStar(R) module (2) from the bracket (3). 10. Remove the module (2) through the opening for the passenger inflator module. INSTALLATION PROCEDURE 1. Install the OnStar(R) module (2) thorough the opening for the passenger inflator module. 2. Pull downward on the back of the I/P compartment to install the module to the bracket (3). 3. Slide the unit upward in the mounting bracket. 4. Connect the electrical connectors (3) to the module (1). 5. Connect the coaxial cable connectors (4) to the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 6152 6. Reposition the module (2) in the bracket. 7. Install the module bracket strap (7) to the mounting bracket (3). 8. Install the bolt (1) for the module bracket strap (7). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 9. Install the I/P bolts on the passenger side. Tighten Tighten the bolt to 2.3 N.m (20 lb in). 10. Install the passenger inflatable restraint module. 11. Enable the SIR. 12. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 13. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 14. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 15. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 15.1. Tell the advisor that this vehicle has received a new VCIM. 15.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 15.3. Follow any additional instructions from the OnStar(R) advisor. 15.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. 16. The default language for voice recognition in the generation 5 OnStar(R) module is English. To change the language resident in the module, refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 6157 Memory Positioning Systems: Description and Operation Vehicle Personalization PERSONALIZATION CHIME LEVEL ADJUSTMENT - RDS RADIOS ONLY In order to adjust the chime level, perform the following steps: 1. Turn the ignition ON. 2. Turn the radio OFF. 3. Press and hold the radio push-button 6 until either LOUD or NORMAL appears on the radio display. The chime sounds 3 times for each volume change. 4. To toggle the setting, press and hold the radio push-button 6 again. PROGRAMMING FEATURES WITH TECH 2 Enter Programming To enter Programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select F0: Body Control Module 5. Select F2: Special Functions 6. Select F2: Personalization Setting Options Select an option with the UP/DOWN ARROW keys. The selected option will be highlighted. Use the SIDE-TO-SIDE ARROW keys to activate or deactivate the highlighted options, an ASTERISK will be displayed when an option has been ACTIVATED. Use the SOFT keys to save the selected options or use the EXIT key to leave the options unchanged. After all options have been selected press the SOFT key to continue. The following is a list of the selectable options: 1. Remote Function Activation (RFA) Audible Unlock Feedback 2. RFA Audible Lock Feedback 3. RFA Visual Feedback 4. Pre-Alarm Horn Chirp Additional Information Refer to Audible Warnings Description and Operation in Instrument Panel, Gages, and Console for more information about the chime. Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about RFA. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 6158 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. For more information on driver personalization features for this vehicle, refer to Driver Personalization. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6167 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6168 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6169 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6170 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6171 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6172 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6173 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6174 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6175 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6176 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6177 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6178 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6179 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6180 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6181 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6182 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6183 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6184 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6185 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6186 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6187 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6188 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6189 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6190 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6191 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6192 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6193 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6194 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6195 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6196 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6197 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6198 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6199 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6200 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6206 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6211 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6217 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 6226 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6235 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6236 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6237 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6238 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6239 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6240 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6241 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6242 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6243 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6244 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6245 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6246 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6247 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6248 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6249 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6250 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6251 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6252 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6253 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6254 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6255 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6256 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6257 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6258 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6259 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6260 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6265 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6266 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6267 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6268 Diagnostic Tips Review Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6269 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6270 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6271 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6272 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6273 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6274 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6275 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6276 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6277 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6278 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6279 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6280 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6281 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6282 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6287 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6288 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6289 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6290 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6291 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6292 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6293 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6294 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6295 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6296 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6297 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6298 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6299 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6300 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6301 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6302 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6303 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6304 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6305 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6306 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6307 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6308 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6309 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6310 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6311 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6312 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6313 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6314 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6315 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6316 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6317 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6318 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6319 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6320 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6325 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6326 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6327 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6328 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6329 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6330 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6331 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6332 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6333 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6334 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6335 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6336 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 6341 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6358 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 6368 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 6377 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6386 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6387 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6388 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6389 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6390 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6391 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6392 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6393 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6394 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6395 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6396 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6397 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6398 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6399 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6400 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6401 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6402 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6403 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6404 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6405 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6406 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6407 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6408 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6409 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6410 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6411 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6416 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6417 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6418 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6419 Diagnostic Tips Review Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6420 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6421 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6422 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6423 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6424 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6425 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6426 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6427 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6428 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6429 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6430 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6431 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6432 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6433 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6438 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6439 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6440 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6441 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6442 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6443 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6444 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6445 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6446 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6447 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6448 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6449 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 6454 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 6471 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 6485 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6494 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6495 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6496 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6497 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6498 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6499 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6500 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6501 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6502 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6503 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6504 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6505 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6506 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6507 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6508 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6509 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6510 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6511 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6512 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6513 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6514 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6515 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6516 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6517 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6518 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 6519 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6524 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6525 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6526 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6527 Diagnostic Tips Review Table Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6528 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6529 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6530 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6531 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6532 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6533 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6534 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6535 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6536 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6537 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6538 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6539 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6540 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 6541 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6546 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6547 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6548 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6549 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6550 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6551 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6552 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6553 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6554 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6555 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6556 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6557 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6558 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6559 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6560 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6561 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6562 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6563 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6564 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6565 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6566 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6567 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6568 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6569 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6570 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6571 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6572 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6573 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6574 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6575 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6576 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6577 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6578 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 6579 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6584 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6585 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6586 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6587 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6588 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6589 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6590 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6591 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6592 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6593 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6594 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 6595 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 6600 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) Amplifier: Diagrams Audio Amplifier (With RPO Code U85) Audio Amplifier (With RPO Code U85) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) > Page 6622 Audio Amplifier (With RPO Code U85) Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) > Page 6623 Audio Amplifier (With RPO Code U85) Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) > Page 6624 Amplifier: Diagrams Audio Amplifier (With RPO Code UQ3) Audio Amplifier (With RPO Code UQ3) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) > Page 6625 Audio Amplifier (with RPO Code UQ3) Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Audio Amplifier (With RPO Code U85) > Page 6626 Audio Amplifier (With RPO Code UQ3) Part 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6627 Amplifier: Description and Operation AUDIO AMPLIFIER The purpose of an amplifier is to increase the power of a voltage or current signal. The output signal of an amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the frequencies of the input signal, as in the case of a subwoofer or a mid-range amplifier. When the radio is turned on, the radio sends a voltage signal to the audio amplifier via the radio on signal circuit. The gain control signal circuit allows the radio to recognize that an amplifier is present. Once the radio detects the amplifier, the radio will output low level audio signals to the amplifier. With the amplifier enabled, the signal that drives the speaker is now amplified. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 6628 Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. Pull back the rear compartment trim panel to gain access to the amplifier. 2. Remove the amplifier nuts. Remove the amplifier from the bracket. 3. Disconnect the electrical connector from the amplifier. INSTALLATION PROCEDURE 1. Connect the electrical connector to the amplifier. 2. Install the amplifier to the bracket. 3. Install the amplifier nuts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 3.5 N.m (31 lb in). 4. Reposition the rear compartment trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation Compact Disc Player (CD): Description and Operation COMPACT DISC FEATURES Compact Disc Features Each item in the list below represents topics covered in detail below: AM/FM Reception - XM Reception - Antenna - Audio Amplifier - Theft Deterrent - Remote Playback Device - Radio Data System (RDS) - XM Satellite Radio - XM Advisory Messages - Radio Chime Level Adjustment - Tape/CD Player Error Messages AM/FM Reception Radio Signal The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal received depends on the following: The power output, or wattage, of the broadcasting station - The location of the vehicle, or receiver, relative to the broadcast tower. - Obstacles between the tower and the receiver - Atmospheric conditions - Which band, AM or FM, the station is broadcasting - Type of antenna and the ground plane AM Reception The AM band has a lower frequency range than the FM band. These longer wavelengths: Bend around obstacles - Follow the curvature of the earth - May reflect, or skip, off the ionosphere The AM frequencies have longer range due to the ground wave. The ground wave follows the curvature of the earth and is affected by its conductivity. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6632 Greater conductivity equates to less signal loss, thus transmission over water is better than over land. The AM band has a range of 80-320 km (50-200 mi). FM Reception The shorter wavelengths of the higher frequency FM band: Reflect off obstacles - Are absorbed by the ground - Penetrate the ionosphere Broadcasts in the FM band are limited to "line of sight" reception which is typically 40 km (25 mi). Even when out of a direct line of sight, the signal may be reflected into areas that would be in a "shadow" otherwise. Factors which affect the line of sight include: Height of the broadcast antenna - Height of the receiving antenna - Terrain and buildings in the broadcast path XM Reception XM satellite radio provides digital radio reception. The XM signal is broadcast from two satellites and, where necessary, terrestrial repeaters. The high power satellites allow the antenna to receive the XM signal even when foliage and other partial obstructions block the antennas view of the satellite. Terrestrial repeaters are used in dense urban areas. These repeaters will receive the satellite signal and re-broadcast them at much higher power levels in order to ensure reception in areas with densely packed tall buildings. Antenna The antenna is comprised of a fixed mast which is mounted on the body of the vehicle. Mast antennas are located typically on the fender or rear quarter panel of the vehicle. Audio Amplifier The purpose of an amplifier is to increase the power of a voltage or current signal. The output signal of an amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the frequencies of the input signal, as in the case of a subwoofer or a mid-range amplifier. When the radio is turned on, the radio sends a voltage signal to the audio amplifier via the radio on signal circuit. The gain control signal circuit allows the radio to recognize that an amplifier is present. Once the radio detects the amplifier, the radio will output low level audio signals to the amplifier. With the amplifier enabled, the signal that drives the speaker is now amplified. Theft Deterrent The "Theftlock" theft deterrent system is a feature on all base and uplevel radios. There is no need to program a security code into the radio as in past model years. The theft deterrent system now utilizes class 2 serial data to determine if the radio is in the appropriate vehicle. Each time the radio receives the "run" power mode message, it compares the VIN information it has stored to the VIN information received from a module on the class 2 serial data circuit responsible for transmitting that information. If a mis-match occurs, the radio display will indicate to the user the radio is locked. Once this takes place, a DTC will set, the radio will not respond to any button presses and become inoperative. The two scenarios able to cause this condition are: A radio is installed from another vehicle. - A module which communicates on the class 2 serial data circuit which supplies VIN information to the radio is replaced and not properly setup with the correct VIN information for that vehicle. The only way to unlock the radio is by using a scan tool. Always refer to the table to diagnose the "Theftlock" DTC for further information. Personal Choice Radio Controls, If Equipped With this feature, your vehicle will recall the latest radio settings as adjusted the last time your vehicle was operated. This feature allows 2 different drivers to store and recall their own radio settings for AM and FM presets, last tuned station, volume, tone and audio source -radio, cassette or CD. The settings recalled by the radio are determined by which transmitter was used to enter the vehicle. After the UNLOCK button is pressed on the transmitter and the ignition is in RUN, the radio settings will automatically adjust to where they were last set by the identified driver. All vehicles are shipped with this feature on. This feature can be disabled by your dealer if desired. Remote Playback Device, If Equipped The remote playback device is either installed at the factory or in some instances it is dealer installed. There are 3 types of remote playback devices, a multi disc remote CD changer, a single disc CD player and a cassette player. All 3 devices have a wiring harness which plugs into the back of the radio. The radio controls and communicates with the remote playback device through a Entertainment and Comfort (E&C;) or Class 2 communication circuit. Remote CD Changer (CDX) The remote CD changer allows for multiple compact disks to be played continuously without having to manually change compact discs. Normal size discs may be played using the slots supplied in the magazine. The magazine must first be loaded with discs before it can played. To load CD's, insert the CDs from bottom to top, placing the discs in the magazine label side up. If a disc is loaded label side down, the disc will not play and an error will occur. Care should be used to align and insert the disc into one disc tray only. Repeat this procedure for loading all of the discs in the magazine. Once the discs are loaded into the magazine, push the magazine into the changer in the direction of the arrow marked on the magazine. When the CD Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6633 magazine is loaded, the changer will begin checking for discs in the magazine. This will continue for up to one and a half minutes, depending on the number of discs loaded. To eject the magazine from the player, push the CD changer door. The door will open. Then press the eject button. Whenever a CD magazine with discs is loaded in the changer, the CD changer symbol will appear on the radio display. If the CD changer is checking the magazine for CDs, the CD symbol will flash on the display until the changer is ready to play. IMPORTANT: If the CD magazine fails to eject after the EJECT button has been pressed, do not attempt to pry the magazine from the CD changer. Radio Data System (RDS) All uplevel audio systems are equipped with technology known as the Radio Data System (RDS). RDS is a system that sends data along with the audio of the FM station you are currently tuned to. RDS is a standard that defines how a FM broadcast station may send digital data along with the audio program. Think of it as a one way wireless modem, allowing the broadcaster to send information about the program to your receiver. RDS data is carried in what is known as a "subcarrier". A subcarrier is a frequency that the FM broadcaster is authorized to use to send data or other audio programs that are not audible in the main audio program. RDS information can be used to display program information and to control the radio. To receive the RDS signal, all that is needed is an FM receiver with an RDS circuit. A special integrated circuit capable of dealing with the RDS signal is in the RDS circuit and passes it along to the receiver's microprocessor where it is decoded and acted upon. RDS Basic Information RDS functions are provided in the FM broadcast band only. - RDS functions will only work with FM broadcast stations that are broadcasting RDS data. - Not all FM Broadcast stations broadcast RDS data or offer all of the RDS services. - RDS functions may not work properly when reception is weak, reception is of poor quality, or RDS is not implemented properly by the FM Broadcaster. In some cases, a radio station broadcasting incorrect information may cause the RDS features of the radio to appear to work improperly. Displaying RDS Information The RDS feature is always on. When tuned to a non-RDS station, the radio will display frequency information as you would normally expect. When tuned to an RDS station, the radio can operate as follows: The radio will change from displaying the frequency of the FM station to displaying the call letters of the station or display the nickname of the station. - Display the type of program. - Display general information such as artist and song title, call in phone numbers, etc. Viewing and Selecting RDS Information for Display Press the TUNE knob once for less than 2 seconds when the radio displays the program service (PS) name and the frequency of the station will be displayed. Press the knob again, and the program type (P-Type) will be displayed. Pressed again, and the program type (PTY) name will be displayed, if the broadcaster is broadcasting one. The PTY name is an eight-character name that the broadcaster may use to further identify the type of programming currently being broadcast. Should you decide that Frequency, P-Type or PTY name is more desirable to display when tuned to an RDS station than the PS name, press the TUNE knob until the desired information is displayed, then press and hold for more than 2 seconds. A beep should be heard and the radio will now display the selected information whenever tuned to an RDS broadcaster. The radio will display frequency for all non-RDS broadcast stations. Using RDS Program Types to Tune Radio Listed are several ways on how to tune your radio using RDS program types. The radio will now be configured to tune based on RDS data rather than frequency. A Fast Way to Find a RDS Station In Your Listening Area 1. Press the PROG TYPE or P-TYPE button, the radio displays the current P-Type to search for. 2. Rotate the TUNE SELECT RCL knob until the radio displays "ANY TYPE". Press the SEEK SCAN button again and the radio will now seek the first RDS Broadcaster of any kind that it can find in the FM band. Finding a RDS Station By Specific Program Type 1. Press the PROG TYPE or P-TYPE button, the radio will display the current P-Type to search for. 2. Rotate the TUNE SELECT RCL knob until the desired program type is shown in the display. 3. Press the SEEK SCAN button and the radio will now seek the first RDS Broadcaster of the selected P-Type. If the radio cannot find the desired P-Type, the radio displays "NOT FOUND" and will return to the last station you were listening to. Using the INFO Feature When the INFO icon appears in the radio display, a new text message is available for viewing. These text messages are from the RDS broadcaster to the listening public and may be general information such as artist and song title, call in phone numbers, etc. How to View the INFO Message Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6634 - To view the message when the INFO icon appears, press the INFO button to display the text message. If you do not press the INFO button again, the text message will automatically be displayed 8 characters at a time, 3 seconds between updates. - To view the text message faster, press the INFO button for less than 1 second to scroll through the message at your own speed. - The INFO icon disappears as soon as you press the INFO button. The INFO icon will appear when a new different message is received. - To view the most recent received message, press the INFO icon at any time, even if the icon does not appear in the display. Controlling the Radio RDS can control the radio when data the receiver can use responds to timely information performing the following: Interrupt the playback of your cassette or CD for traffic or emergency bulletins. - Search for stations by type of program. - Automatically follow networked programming from transmitter to transmitter as you travel from one listening area to another. - Set your clock to the time that the RDS broadcast station broadcasts. Using the RDS Traffic Feature Some RDS broadcasters may carry traffic information programming to inform you of current traffic conditions in your listening area and is indicated by the TRAF icon in the radio display. RDS enables the broadcaster to get this information to you even when you are listening to a tape or compact disc. This feature can be enabled or disabled by the listener. Press the TRAF button to find a station that claims to carry traffic information. You may do this even when playing a cassette tape or compact disc. This action will operate in the background without interrupting the current playback. If the radio is not currently tuned to an RDS traffic station, the radio will immediately seek an RDS traffic station. If the radio finds an RDS traffic station, the "TRAF" icon will appear on the radio display as will brackets around the [TRAF] icon. If the radio cannot find an RDS traffic station after searching through the entire FM band, the radio will display "NO TRAFFIC". Traffic Interrupt Feature Whenever the TRAF icon is displayed, the current FM station may also broadcast traffic announcements. Traffic announcements are reports of the current traffic conditions in the listening area of the tuned FM broadcasters. Your radio can interrupt the playback of a cassette or compact disc by use of the traffic interrupt feature. The traffic interrupt feature is enabled when the TRAF icon is displayed. If the broadcaster sends out a traffic announcement while you are listening to FM or in the playback mode, "TRAFFIC" will be displayed on the radio and the audio from the broadcaster will be heard. At the conclusion of the traffic announcement, the radio will return to the previous playback mode. During the time the radio displays "TRAFFIC", you can adjust the volume of the traffic announcement. This will be the volume at which all future traffic announcements will be heard until the volume during another traffic announcement. You can also interrupt a traffic announcement interrupt by pressing the TRAF button. RDS Program Type Interrupts When the Program Type feature is on, all program types may be selected as interrupts. Perform the following to select a program type as an interrupt. 1. Turn ON the radio. 2. Select the program type. 3. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds while the program type is displayed. When an interrupt is set, the display shows the program type followed by an asterisk and the brackets around the [P-TYPE] icon are illuminated. To turn an interrupt off: 1. Select a program type marked as an interrupt. 2. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds. The program type will be unmarked by turning off the asterisk. If no other program type interrupts are set, the brackets around the [P-TYPE] icon are also turned off. When a Program Type Interrupt is set, the radio will wait for the current FM RDS station to change its program type to one of those selected as an interrupt. When the station program type changes to a program type interrupt setting then the interrupt is activated. If the radio is in a playback mode, an interrupt will cause the radio to switch to the FM band, display the program type followed by "INT", and adjust the volume to the last active interrupt volume. If the radio is in the FM mode when an interrupt occurs, only the volume will change. The radio resumes the mode that was active prior to the interrupt, when an interrupt ends. An interrupt in progress may be canceled by pressing the program type button or a mode button. During a national or local emergency, a special program type interrupt message "ALERT!" is displayed. This special announcement will cancel all other RDS features that are in progress, such as a traffic announcement. Alternate Frequency (AF) Switching RDS permits broadcaster's to send information to the radio that allows the radio to automatically switch frequency to the best quality station in that broadcaster's network. Since the radio is displaying the broadcaster call letters or nickname, the listener will not see the frequency during an AF switch unless you have changed the default display to be frequency instead of Program Service name. To enable or disable AF switching perform the following: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6635 - Press and hold the AM/FM or BAND button for two seconds or more. - The radio will display "AF ON" or "AF OFF" depending on the current condition of AF and a confirmation beep will be heard. When AF is enabled and you recall an RDS station stored on preset, the radio determines if the station stored is of acceptable quality. If not, the radio checks all available AF's for your station. If the radio fails to locate your program, "AF SEARCH" will be displayed as the radio scans across the band looking for your program or an affiliated network. If the radio cannot find the original station or an acceptable alternate frequency "NOT FOUND" will be displayed and the radio returns to the original frequency for the preset. RDS Clock Time Broadcasters can choose to send clock time information in the RDS data. This information can be used to update the clock time on the radio. RDS clock time is broadcasted once a minute. To set the clock using RDS clock data perform the following: Press and hold the HR and MIN buttons together for two or more seconds to update the time. - The display will show "UPDATED" after receiving the broadcasted time data. - If the broadcaster is not broadcasting the time data, the radio will display "NO UPDATE" and the time remains unchanged. XM Satellite Radio XM is a national satellite radio service that offers up to 100 coast to coast channels including music, news, sports, talk and children's programming. XM provides digital quality audio and text information, including song title and artist name. A service fee is required in order to receive the XM service. For more information, contact XM at www.xmradio.com or call 1-800-852-9696. Digital Radio Receiver The radio controls communicate with the digital radio receiver via the class 2 communication circuit. The digital radio receiver sends remote radio audio signals to the radio. Viewing Messages Press the DISP or RCL button while in XM mode to view various pieces of information related to the current song or channel. By pressing and releasing the DISP or RCL button, you may view four different categories of information: Artist Name/Feature, Song/Program Title, Channel Category, and other Additional Information that may be broadcast on that channel. Additional Information messages may not always be available. If an Additional Information message is being broadcast on the tuned channel, the INFO icon will appear on the display. Each of the four information types may have multiple pages of text. To reach a category, press and release the DISP or RCL button consecutively until the desired type is displayed. If there are multiple pages of text for the selected information type, the radio will automatically display all the pages for that type at a rate of approximately one page every three seconds before timing out and returning to the default display. You may override this feature by pressing the DISP or RCL button to review all of the pages at your own pace. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6636 XM Advisory Messages Radio Chime Level Adjustment IMPORTANT: Radio chime level adjustment is only available on radios equipped with RDS. The radio is the vehicle chime producer. The chime is audible from the driver's side front door speakers. To adjust the chime level louder. 1. Turn ON the ignition. 2. Turn OFF the radio. 3. Press and hold preset button 6. The chime volume level will change from the normal level to loud. The radio displays "LOUD". To change back to the default or normal setting follow the previous steps. The chime volume level will change from the loud level to normal. The radio displays "NORMAL". Each time the chime volume is changed, the radio sounds three chimes as an example of the new volume selected. Tape/CD Player Error Messages The radio displays an error when any of the following occurs. The radio will display error codes for the tape player and integral CD player. - The radio will display the following tape player error codes for tight tape, broken tape, and wrapped tape. If these conditions are detected, the radio will switch to the radio mode and eject the tape. The error code will be displayed for 5 seconds, followed by the tuner display, then the default. E10 or TIGHT TAPE-Tight tape - E11 or BROKEN TAPE-Broken tape - E14 or WRAPPED TAPE-Wrapped tape - The radio will display the following integral CD player error codes. If one of these problems is detected, the unit will switch to the radio mode and Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 6637 eject the CD. The display will show TOD, if the unit is off, or display the radio frequency for 5 seconds, then the default, if the unit is on. E20 or CHECK CD-Optics focus error, maybe due to moisture - E21 or CHECK CD-Optics loss of tracking control, maybe due to blemishes on disc - E22 or PLAYER ERR-Load/Unload motor problem - E23 or PLAYER ERR-Communication problem Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles Speaker: Customer Interest Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles > Page 6651 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles Speaker: All Technical Service Bulletins Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles > Page 6657 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) Speaker - LF (With RPO Code UX7) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6660 Speaker - LF (With RPO Code UW6/UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6661 Speaker - LF (With RPO Code U79) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6662 Speaker - LF (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6663 Speaker: Diagrams Speaker - LF (With RPO Code UX7) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6664 Speaker - LF (With RPO Code UW6/UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6665 Speaker - LF (With RPO Code U79) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6666 Speaker - LF (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6667 Speaker - LR (With RPO Code UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6668 Speaker - LR (With RPO Code UX7/UW6) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6669 Speaker - LR (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6670 Speaker - RF (With RPO Code UW6/UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6671 Speaker - RF (With RPO Code UX7) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6672 Speaker - RF (With RPO Code U79) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6673 Speaker - RF (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6674 Speaker - RR (With RPO Code UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6675 Speaker - RR (With RPO Code UX7/UW6) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6676 Speaker - RR (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6677 Tweeter - LF (With RPO Code UW6/UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6678 Tweeter - LF (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6679 Tweeter - RF (With RPO Code UW6/UQ3) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Speaker - LF (With RPO Code Code UX7) > Page 6680 Tweeter - RF (With RPO Code U85) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Grille Replacement - Front Speaker: Service and Repair Speaker Grille Replacement - Front SPEAKER GRILLE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front door trim panel (3) from the inner door. IMPORTANT: The tweeter speaker is not serviced separately from the speaker grille. Replace as an assembly. 2. Remove the retaining nuts (2) form the speaker grille on the back side of the trim panel (3). 3. Remove the speaker grille (1) from the trim panel (3). INSTALLATION PROCEDURE 1. Install the speaker grille (1) to the trim panel (3). 2. Install the retaining nuts (2) to the speaker grille (1) on the back side of the trim panel (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 1 N.m (9 lb in). 3. Install the trim panel to the inner door (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Grille Replacement - Front > Page 6683 Speaker Replacement Reference Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Grille Replacement - Front > Page 6684 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the front door trim panel. 2. Disconnect the electrical connectors (1) and (2) from the speaker. 3. Remove the bolts (3) from the speaker. 4. Remove the front door speaker from the front door. INSTALLATION PROCEDURE 1. Install the front door speaker to the door. 2. Install the front door speaker bolts (3) to the speaker. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 1.9 N.m (17 lb in). 3. Connect the electrical connector (1) and (2) to the speaker. 4. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Grille Replacement - Front > Page 6685 Speaker: Service and Repair Speaker Replacement - Rear SPEAKER REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear window panel trim. 2. Press the tab on the front of the rear speaker spacer (3). 3. Remove the speaker spacer (3) lifting up and out. 4. Disconnect the electrical connector (1) from the speaker (2). 5. Remove the rear speaker spacer (3) from the vehicle. 6. Remove the screws (1) from rear speaker (3). 7. Remove the rear speaker (3) from the spacer (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Grille Replacement - Front > Page 6686 1. Install the rear speaker (3) to the rear speaker spacer (2). 2. Install the rear speaker screws (1) to the rear speaker (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). 3. Connect the electrical connector (1) to the rear speaker (2). 4. Position the rear speaker spacer tabs (3) to the slots in the rear shelf. 5. Install the rear speaker (2) to the rear shelf by pressing into place until fully seated. 6. Install the rear window panel trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation Cassette Features Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams Accessory Delay Module: Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 6694 Retained Accessory Power (RAP) Diagram 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 6695 Accessory Delay Module: Description and Operation SERIAL DATA CONTROLLED RETAINED ACCESSORY POWER, RAP Retained accessory power, RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The Audio system on this vehicle is the only device that is controlled by RAP. SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER, RAP The Radio receives a RAP message from the Body Control Module, BCM over the serial data circuits. The BCM module monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM module then sends a message to the Radio telling it that it is in RAP power mode. RAP will end when one of the following conditions are met: The BCM module receives an input from the drivers door jam switch. - The BCM module receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM module detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM module then sends a serial data message to the Radio ending the RAP function. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Accessory Delay Module DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with the Diagnostic System Check - Accessory Delay Module. The diagnostic system check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes DTCs and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Accessory Delay Module DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION Steps 1-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6698 Steps 3-7 The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 3. This step tests for valid system power moding in all ignition switch positions. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6699 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms - Accessory Delay Module SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the RAP feature. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative Retained Accessory Power (RAP) - Inoperative RETAINED ACCESSORY POWER (RAP) INOPERATIVE DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module , BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6700 Steps 1-5 Retained Accessory Power (RAP) - On After Timeout RETAINED ACCESSORY POWER (RAP) ON AFTER TIMEOUT DIAGNOSTIC AIDS All Retained Accessory Power, RAP functions on this vehicle are controlled by the Body Control Module, BCM using Class 2 serial data. If Class 2 communication between the Radio, BCM and Data Link Connector is functioning properly, and the door ajar switches are working properly, replace the BCM. TEST Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6701 Steps 1-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6702 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Use the Scan Tool Data Display Values and Definitions Information in order to assist in diagnosing vehicle malfunctions. Compare the vehicles actual scan tool data with the typical data display value table information. Use the data information in order to aid in understanding the nature of the problem when the vehicle does not match with the typical data display values. The scan tool data values were taken from a known good vehicle under the following conditions: - The ignition switch is in the ON position. - The engine is not running. - The vehicle is in PARK. Accessory: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or ACCY position. Battery Voltage: This voltage value refers to the battery system voltage. Driver Door Ajar Sw.: The scan tool displays On/Off. On is displayed when the driver door is open, Off when closed. Ignition 1: The BCM uses this data in order to determine the position of the ignition switch. ON is displayed when the ignition switch is in the ON or CRANK position. Key In Ignition: This information refers to whether or not the ignition key is inserted into the ignition switch. The BCM uses this data to perform chime functions. ON is displayed when the key is inserted into the ignition switch. Passenger Door Ajar Sw.: The scan tool displays On/Off. On is displayed when at least one passenger door is open, Off when all passenger doors are closed. Scan Tool Data List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6711 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6712 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6713 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6714 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6715 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6716 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6717 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6718 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6719 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6720 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6721 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6722 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6723 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6724 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6725 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6726 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6727 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6728 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6729 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6730 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6731 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6732 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6733 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6734 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6735 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6736 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6737 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6738 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6739 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6740 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6741 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6742 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6743 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6744 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6750 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6755 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6760 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6761 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6767 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6776 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6777 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6778 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6779 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6780 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6781 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6782 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6783 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6784 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6785 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6786 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6787 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6788 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6789 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6790 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6791 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6792 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6793 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6794 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6795 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6796 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6797 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6798 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6799 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6800 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6801 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6806 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6807 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6808 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6809 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6810 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6811 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6812 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6813 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6814 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6815 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6816 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6817 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6818 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6819 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6820 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6821 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6822 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6823 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6824 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6825 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6826 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6827 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6828 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6829 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6830 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6831 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6832 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6833 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6834 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6835 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6836 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6837 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6838 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6839 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6844 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6845 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6846 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6847 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6848 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6849 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6850 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6851 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6852 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6853 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6854 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6855 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 6860 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6873 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6878 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6879 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 6885 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6894 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6895 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6896 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6897 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6898 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6899 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6900 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6901 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6902 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6903 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6904 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6905 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6906 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6907 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6908 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6909 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6910 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6911 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6912 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6913 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6914 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6915 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6916 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6917 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6918 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6919 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6924 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6925 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6926 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6927 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6928 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6929 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6930 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6931 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6932 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6933 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6934 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 6935 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 6940 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 6953 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6958 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 6959 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6969 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6970 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6971 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6972 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6973 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6974 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6975 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6976 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6977 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6978 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6979 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6980 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6981 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6982 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6983 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6984 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6985 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6986 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6987 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6988 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6989 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6990 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6991 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6992 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6993 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 6994 Circuit/System Testing Component Testing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 6999 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7000 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7001 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7002 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7003 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7004 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7005 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7006 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7007 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7008 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7009 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7010 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7011 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7012 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7013 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7014 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7015 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7016 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7017 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7018 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7019 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7020 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7021 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7022 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7023 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7024 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7025 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7026 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7027 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7028 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7029 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7030 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7031 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7032 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7037 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7038 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7039 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7040 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7041 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7042 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7043 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7044 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7045 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7046 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7047 Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 7048 Labor Time Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 7053 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Disable the SIR. 2. Remove the passenger inflatable restraint module. 3. Remove the I/P carrier bolts on the passenger side. 4. Remove the bolt (1) for the module bracket strap (7). 5. Remove the module bracket strap (7) from the mounting bracket (3). 6. Slide the module (2) upward in the mounting bracket. IMPORTANT: The generation 5 module uses four connector cavities. In addition, the STID and the ESN information on the generation 5 label can not be used to update the customer account information if the module is replaced. Use a scan tool to access this information. 7. Disconnect all the electrical connector (3) from the communication interface module (1). 8. Disconnect all the coaxial cable connectors (4) from the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 7065 9. Pull downward on the back of the I/P compartment to remove the OnStar(R) module (2) from the bracket (3). 10. Remove the module (2) through the opening for the passenger inflator module. INSTALLATION PROCEDURE 1. Install the OnStar(R) module (2) thorough the opening for the passenger inflator module. 2. Pull downward on the back of the I/P compartment to install the module to the bracket (3). 3. Slide the unit upward in the mounting bracket. 4. Connect the electrical connectors (3) to the module (1). 5. Connect the coaxial cable connectors (4) to the module (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 7066 6. Reposition the module (2) in the bracket. 7. Install the module bracket strap (7) to the mounting bracket (3). 8. Install the bolt (1) for the module bracket strap (7). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 4 N.m (35 lb in). 9. Install the I/P bolts on the passenger side. Tighten Tighten the bolt to 2.3 N.m (20 lb in). 10. Install the passenger inflatable restraint module. 11. Enable the SIR. 12. Install the scan tool. Use the special functions menu in order to perform the OnStar(R) setup procedure for this vehicle. IMPORTANT: After replacing the vehicle communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. In addition, pressing and holding the white dot button on the keypad will NOT reset this version of the OnStar(R) system. This action will cause a DTC to set. 13. Move the vehicle to an open area that is away from tall buildings and with a clear view of unobstructed sky. Allow the vehicle to run for 10 minutes. 14. Use the ID information menu on the scan tool to access the new station ID (STID) and the electronic serial number (ESN) from the new VCIM. 15. Press the blue OnStar(R) button to connect to the OnStar(R) Call Center and perform the following procedure: 15.1. Tell the advisor that this vehicle has received a new VCIM. 15.2. Ask the advisor to add the new STID and the ESN to update the customer's account. 15.3. Follow any additional instructions from the OnStar(R) advisor. 15.4. Ask the advisor to activate the OnStar(R) Personal Calling feature, if available. 16. The default language for voice recognition in the generation 5 OnStar(R) module is English. To change the language resident in the module, refer to Service Programming System (SPS) (Remote Procedure)Service Programming System (SPS) (Pass-Thru Procedure)Service Programming System (SPS) (Off Board Remote Procedure)Service Programming System (SPS) (Off Board Pass-Thru Procedure) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7075 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7076 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7077 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7083 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7084 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7085 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7094 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7095 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 7096 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7102 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7103 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 7104 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock(TM) Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Page 7109 Lock Cylinder Switch: Description and Operation IGNITION LOCK CYLINDER CASE, INCLUDING THE PASSLOCK(TM) SENSOR The ignition lock cylinder fits inside the ignition lock cylinder case and operates the ignition switch when turned by a key with the proper mechanical cut. When the ignition key is used to turn the ignition lock cylinder to crank, start, a magnet on the lock cylinder passes close to the Passlock(TM) Sensor within the ignition lock cylinder case. The magnet activates the Security Hall Effect Sensor in the Passlock(TM) Sensor which completes a circuit from the security sensor signal circuit through a resistor to the security sensor low reference circuit. The resistance value will vary from vehicle to vehicle. If a magnet from outside of the ignition lock cylinder case is used to attempt to steal the vehicle, the Tamper Hall Effect Sensor will be activated. This completes a circuit from the security sensor signal circuit through a tamper resistor to the security sensor low reference circuit bypassing the security resistor. If the ignition switch is forced to rotate without the correct key, or if the ignition lock cylinder is removed by force, the Passlock(TM) Sensor will be damaged and will not operate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7122 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7123 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7124 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7125 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7126 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Recreational (Dinghy) Towing Information > Page 7127 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations Location View Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) Body Control Module: Description and Operation Body Control Module (BCM) BODY CONTROL MODULE The various BCM input and output circuits are described in the corresponding functional areas indicated on the BCM electrical schematics. The Body Control Module functions include the following. - Retained Accessory Power, RAP, Audio System only. - A/C compressor request. - Remote Function Control. - A/C cooling Fan. - Exterior and interior lighting control Daytime running lights (DRL) - Automatic lighting control - Fog lamps - Interior lighting. - Battery rundown protection (Inadvertent Power). - Chimes. Key In Ignition - Head Lamps On - Seat Belt Not Fastened - Turn Signal On - Park Brake Warning - Door Ajar Warning - Check gauges - Gauge control. - Instrument cluster indicator control. - Theft deterrent. - Engine coolant level sensing. - Key-in-ignition sensing. - Brake fluid level sensing. - Parking brake state sensing. - Rear compartment interface. - Horn interface. - Door lock interface. - Bulb Check. - ETS -Pontiac Only. - A/T Shift lock control. The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 7135 Body Control Module: Description and Operation Content Theft Deterrent (CTD) CONTENT THEFT DETERRENT (CTD) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. When the BCM detects an unauthorized entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active. The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Body Control Module (BCM) > Page 7136 Body Control Module: Description and Operation Vehicle Theft Deterrent (VTD) CONTENT THEFT DETERRENT (CTD) The BCM contains the logic of the theft deterrent system. The BCM provides the battery positive voltage to operate the Passlock(TM) Sensor. The BCM also measures the voltage of the security sensor signal circuit. The voltage measured will indicate whether the Passlock(TM) Sensor has been activated and whether the resistance value from the sensor is a valid value or the tamper value. If voltage measured is in the valid range, the BCM compares this voltage, voltage code, to a previously learned voltage code. If the voltage codes match, the BCM sends a class 2 message containing a password to the PCM. If the voltage codes do not match, or the voltage is in the Tamper range, or there is a circuit fault, the BCM will not send the correct password to the PCM, and the vehicle will not start. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION 1. The body control module (BCM) must be programmed with the proper RPO configurations. The BCM stores the information regarding the vehicle options and if the BCM is not properly configured with the correct RPO codes, the BCM will not control all of the features properly. Ensure that the following conditions exist in order to prepare for BCM programming: The battery is fully charged. - The ignition switch is in the ON position. - The data link connector (DLC) is accessible. - All disconnected modules and devices are reconnected before programming. 2. To setup a new BCM, access the SPECIAL FUNCTIONS menu on the scan tool to program the BCM. Select NEW BCM SETUP and follow the instructions on the scan tool. 3. If the BCM fails to accept the program, perform the following steps: - Inspect all BCM connections. - Verify that the scan tool has the latest software version. Passlock Learn Procedures IMPORTANT: If any module or device listed is replaced, programming of the module must be done prior to performing the Passlock Learn procedure. Perform the Learn Procedure if any of the following components have been replaced: The body control module (BCM) - The Passlock sensor - The powertrain control module (PCM) IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 7139 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Release the body control module (BCM) wire harness retainer from the BCM bracket. 3. Disconnect the BCM electrical connectors from the BCM. 4. Release the lock tabs and remove the BCM from the BCM bracket. 5. Remove the BCM bracket nuts (2) if required. 6. Remove the BCM bracket (1) as an assembly if required. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 7140 1. Install the BCM bracket (1) as an assembly if required. 2. Install the BCM bracket nuts (2) if required. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Install the BCM into the BCM bracket until lock tabs are fully seated. 4. Connect the BCM electrical connectors to the BCM. 5. Install the BCM wire harness retainer to the BCM bracket. 6. Connect the negative battery cable. 7. Reprogram the BCM. See: Testing and Inspection/Programming and Relearning Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7147 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement (Chevrolet) Removal Procedure 1. Remove the front fender liner from the fascia. 2. Remove the hood latch close out panel. 3. Remove the headlamp assemblies. 4. Remove the fasteners that attach the front fascia bracket to the front impact beam. 5. Disconnect the fog lamp electrical connectors, if equipped. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7148 6. Remove the center fastener that attaches the fascia to the fender. Access the fastener from the top, through the headlamp openings. 7. Disengage the fascia from the shoulder bolts by pulling the fascia outward at the fenders. 8. Remove the front bumper fascia from the vehicle. Installation Procedure 1. Position the front bumper fascia on the vehicle. 2. Push the fascia onto the shoulder bolts at the fender joint. Notice: Refer to Fastener Notice in Service Precautions. 3. Accessing through the headlamp opening, install the bolt that attaches the fascia to the fender. Tighten the bolt to 9 N.m (80 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7149 4. Connect the fog lamp electrical connectors, if equipped. 5. Install the fasteners that attach the fascia brackets to the bumper beam. 6. Install the headlamps. 7. Install the hood latch close out panel. 8. Install the front fender liner to the front fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 7154 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement Removal Procedure 1. Raise and support the vehicle.Refer to Vehicle Lifting. 2. Remove the front fascia. 3. Disconnect the wiring harness and components from the font impact beam. 4. Remove the nuts from the front bumper impact bar. 5. Remove the front bumper impact bar. Installation Procedure 1. Install the front bumper impact bar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 7155 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nuts to the front bumper impact bar. Tighten the front bumper impact bar nuts to 150 N.m (111 lb ft). 3. Install the wiring harness and the components to the impact beam. 4. Install the front fascia. 5. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Service and Repair Front Bumper Shock Absorber: Service and Repair Front Bumper Fascia Energy Absorber Replacement (Chevrolet) Removal Procedure 1. Remove the front bumper fascia. 2. Remove the fasteners that attach the energy absorber to the fascia. 3. Remove the energy absorber from the front fascia. Installation Procedure 1. Position the energy absorber into the front fascia. 2. Install the fasteners that attach the energy absorber to the fascia. 3. Install the front fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7164 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Replacement (Chevrolet) Removal Procedure 1. Open the rear compartment lid. 2. Pull back and remove the rear compartment trim as required. Refer to Rear Compartment Trim Panel Replacement in Trunk/Liftgate. 3. Remove the fasteners that attach the rear fascia to the quarter panel. 4. Raise and support the vehicle.Refer to Vehicle Lifting. 5. Remove the screws from the rear fascia in the rear wheel opening. 6. Remove the center pins on each of the four retaining tabs to release the retaining tabs from the lower center of the rear fascia. 7. Perform the following steps to remove the rear fascia: 1. Put down a protective cover to prevent damage to the rear fascia. 2. With the aid of an assistant, pull both corners of the rear fascia away from the quarter panel. 3. Pull the rear fascia from the center of the rear impact bar. 8. Disconnect the electrical connector from the rear fascia. 9. Remove the rear license plate lamp socket and bulb. 10. Remove the rear fascia brackets from the rear fascia. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7165 1. Install the rear fascia brackets into the rear fascia. 2. Install the rear license plate lamp socket and bulb. 3. Install the electrical connector to the rear fascia. 4. Perform the following steps to install the rear fascia: 1. Align the rear fascia to the center of the rear impact bar. 2. With the aid of an assistant, fit both corners of the rear fascia to the quarter panel. 5. Install the push pin fasteners to the lower center tabs of the rear fascia. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the screws to the rear fascia in the rear wheel opening. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Page 7166 Tighten the screws to 3 N.m (27 lb in). 7. Lower the vehicle. 8. Install the screws that attach the rear fascia to the quarter panel. Tighten the screws to 3 N.m (27 lb in). 9. Install the rear compartment trim as required. 10. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 7171 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Remove the energy absorber. 3. Remove the nuts from the impact bar. 4. Remove the impact bar. Installation Procedure 1. Position the impact bar to the rear end structure. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 7172 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the impact bar retaining nuts. Tighten the nuts to 30 N.m (22 lb ft). 3. Install the energy absorber. 4. Install the rear bumper fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Shock Absorber > System Information > Service and Repair Rear Bumper Shock Absorber: Service and Repair Rear Energy Absorber Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Remove the push-in retainers from the rear bumper energy absorber. 3. Remove the rear bumper energy absorber from the impact bar. Installation Procedure 1. Position the rear bumper energy absorber to the impact bar. 2. Install the push-in retainers to the rear bumper energy absorber. 3. Install the rear bumper fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear bumper fascia. 2. Pull back the rear compartment trim from the right rear corner in order to expose the quarter outer panel pressure relief valve. 3. Remove the quarter outer panel pressure relief valve (1). Disengage the tabs from the inside of the rear compartment. Installation Procedure 1. Install the pressure relief valve (1) by sliding the valve into the opening and engaging the tabs. Fully engage the retaining tabs. 2. Install the rear compartment trim. 3. Install the rear bumper fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arm assemblies. 3. Disconnect the washer tubing from the air inlet screen. 4. Using J 38778, remove the air inlet grille panel push-in retainers (1) from the panel. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Install the air inlet grille panel push-in retainers (1) to the panel. 3. Connect the washer tubing to the air inlet panel. 4. Install the wiper arms and blade assemblies. 5. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Adjustments Front Door Exterior Handle: Adjustments Front Side Door Outside Handle Rod Adjustment Removal Procedure 1. Raise the window to the full UP position. 2. Remove the door trim panel. 3. Remove the door water deflector in order to access the door handle rod. 4. Remove the lower window channel retainer. 5. Use a small flat-bladed screwdriver in order to remove the outside handle rod (2) from the door lock assembly. 6. Remove the outside handle rod (2) from the outside handle (1). 7. Remove the outside handle rod (1). Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Adjustments > Page 7190 1. Install the outside handle rod (2) to the outside handle (1). 2. Position the outside handle in the closed position. 3. Clip the outside handle rod (2) to the door lock assembly. 4. Install the lower window channel retainer. 5. Install the door water deflector. 6. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Adjustments > Page 7191 Front Door Exterior Handle: Service and Repair Door Outside Handle Replacement Removal Procedure 1. Remove the door trim panel. 2. Pull back the water deflector to access the door handle rod. 3. Lift the door outside handle (1). 4. Drill out the rivets (2) from the door outside handle. 5. Remove the rod from the door outside handle (2). 6. Remove the door outside handle (1) from the door. Installation Procedure 1. Position the door handle (1) to the door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Adjustments > Page 7192 2. Install the rod to the door outside handle (2). 3. Pull back the water deflector. 4. Install the door outside handle (1). 5. Lift the outside handle (1) and install the rivets (2) to the handle. 6. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Inside Handle Replacement Tools Required J 34940 Rivet Gun Removal Procedure 1. Raise the window to the full UP position. 2. Remove the trim panel. 3. Drill out the inside handle rivet (1). 4. Slide the door inside handle (2) rearward in order to disengage the tabs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 7197 5. For the front door, remove both rods (2, 5) from the inside door handle (3). For the rear door, remove the handle rod. 6. Remove the inside handle (3) from the door. Installation Procedure 1. For the front door, Install both rods (2, 5) to the inside door handle (3). For the rear door, install the handle rod to the door handle. 2. Slide the inside handle (3) forward in order to engage the tabs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 7198 3. Install the inside handle rivet (1). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 7199 Front Door Interior Handle: Service and Repair Door Handle Components Front Door Inside Handle Rod Replacement Removal Procedure 1. Raise the window to the full UP position. 2. Remove the door trim panel. 3. Remove the inside handle rivet. 4. Slide the inside handle rearward in order to disengage the tabs. 5. Remove both rods from the inside door handle. The rods are identified by the following colors: * The left hand rod (3) is red. * The right hand rod (2) is green. 6. Remove the door water deflector in order access the door lock assembly. 7. Remove the door lock assembly. Installation Procedure 1. Install the door lock assembly. 2. Install the door water deflector. 3. Install both rods to the inside door handle. The rods are identified by color as follows: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 7200 * The left hand rod is red (3). * The right hand rod is green (2). 4. Slide the inside handle forward in order to engage the tabs. 5. Install the inside handle rivet. 6. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Replacement Front Door Hinge: Service and Repair Door Hinge Replacement Front Side Door Hinge Replacement Removal Procedure Important: In order to minimalize door realignment, do not remove both door hinges at the same time. Do each door hinge separately, and replace the broken door hinge first. 1. Open and support the door. 2. Clean the mounting surfaces of the hinges with a clean rag and mark the front door hinge locations on each surface with a grease pencil or other suitable marker. 3. Remove the front door. 4. Remove the hinge to pillar bolts and nuts. 5. Remove the front door hinge from the vehicle. Installation Procedure 1. Position the front door hinge to the alignment marks on the pillar. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts and nuts attaching the front door hinge to the pillar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Replacement > Page 7205 Tighten the front door hinge bolts and nuts to 26 N.m (18 lb ft). 3. Install the front door. 4. Remove the support from the front door. 5. Inspect the door for proper operation and alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Door Hinge Replacement > Page 7206 Front Door Hinge: Service and Repair Front Side Door Hinge Spring Replacement Front Side Door Hinge Spring Replacement Tools Required J 36604 Door Hinge Spring Compressor Removal Procedure 1. Remove the upper door hinge. 2. Install the J 36604 in order to capture as many door hinge spring coils as possible. 3. Using a hammer, tap the J 36604 in order to fully seat the J 36604 onto the door hinge spring. 4. Tighten the bolt on the J 36604 in order to fully compress the door hinge spring. 5. Remove the J 36604 and the door hinge spring from the door hinge assembly. 6. Loosen the bolt on the J 36604. 7. Remove the door hinge spring from the J 36604. Installation Procedure 1. Install the door hinge spring into the J 36604. Ensure that only the top coil and the bottom coil are outside of the J 36604. 2. Tighten the bolt on the J 36604 in order to fully compress the door hinge spring. 3. Install the J 36604 and the door hinge spring to the door lower hinge. 4. Loosen the bolt on the J 36604. 5. Remove the J 36604. 6. Install the upper door hinge. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-08-59-003 > Oct > 03 > Audio System/Interior Right Front Speaker Rattles Front Door Panel: Customer Interest Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-08-59-003 > Oct > 03 > Audio System/Interior Right Front Speaker Rattles > Page 7215 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles Front Door Panel: All Technical Service Bulletins Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-08-59-003 > Oct > 03 > Audio System/Interior - Right Front Speaker Rattles > Page 7221 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises Wheel Cover: All Technical Service Bulletins Wheels - Front/Rear Wheel Squeaking Noises Bulletin No.: 01-03-10-005C Date: October 22, 2003 TECHNICAL Subject: Wheel Squeak (Install Wheel Cover Insulators) Models: 2000-2004 Chevrolet Cavalier with 14 and 15 Inch Wheel Covers 2000-2002 Pontiac Sunfire with 14 Inch Wheel Cover 2003-2004 Pontiac Sunfire with 15 Inch Wheel Cover 2000 Toyota Cavalier with 14 and 15 Inch Wheel Covers Supercede: This bulletin is being revised to update model years and provide additional material information for 2003 and 2004 vehicles. Please discard Corporate Bulletin Number 01-03-10-005B (Section 03 Suspension). This bulletin contains two different corrections; use the appropriate procedure depending on the model year of the vehicle. Condition Some customers may comment about a squeak type noise coming from the front or rear wheels. This condition is most apparent during cold weather and while driving at low speeds (0-24 km/h (0-15 mph)). Cause This condition may be caused by hard contact between the inner edge of the wheel cover and the outer edge of the steel rim. Correction (2000-2002 Model Year) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 7227 Install insulators on the backside of all four wheel covers. Use the following service procedure and the part numbers listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 7228 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. Important: There is no tolerance allowed for gaps between the insulator and the wheel cover lip. It is also ideal to have the insulator flush (1) against the rib, but there is a tolerance of up to 6 mm (0.236 in) for a gap (2) between the insulator and the rib. 5. Peel the red non-stick backing off of the insulator. 6. Carefully place the insulator onto the wheel cover so that the area under the lip is resting against the corner of the inside edge of the wheel cover lip. 7. Rotate the insulator until it is flush against the inside edge of the wheel cover lip. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 7229 9. Place another insulator in the next location by repeating Steps 5 through 8. There should be 10 insulators placed on each wheel cover. Correction (2003 and 2004 Model Years) Install insulator tape on the backside of all four wheel covers. Use the following procedure listed below. 1. Remove the wheel covers. 2. Clean the backside of each wheel cover using a mild liquid detergent in a distilled or deionized water solution. Rinse each wheel cover with clean water. 3. Dry each wheel cover using compressed air or a clean, lint-free, non-abrasive cloth. 4. After the wheel covers are completely dry, each wheel cover should be wiped with isopropyl alcohol on a clean, lint-free, non-abrasive cloth at the insulator locations. Refer to the illustrations above. 5. Cut (40-Cavalier or 36-Sunfire) 7 mm (.275 in) lengths of *3M(R) Squeak Reduction Tape 5430, P/N 06356. 6. Peel the non-stick backing off tape. 7. Carefully place the tape (insulator) onto the wheel cover's backside, outer most edge, as shown. 8. Press down firmly on the insulator to ensure that the adhesive is bonding to the wheel cover. 9. Repeat steps 6 through 8 with the remaining insulators. There should be (10-Cavalier or 9-Sunfire) insulators placed on each wheel cover. Important: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 01-03-10-005C > Oct > 03 > Wheels - Front/Rear Wheel Squeaking Noises > Page 7230 Also, place an insulator onto the wheel cover's backside at the location of the clip-on wheel balance weight. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 7231 Front Door Panel: By Symptom Technical Service Bulletin # 03-08-59-003 Date: 031013 Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 7232 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 03-08-59-003 Date: 031013 Audio System/Interior - Right Front Speaker Rattles Bulletin No.: 03-08-59-003 Date: October 13, 2003 TECHNICAL Subject: Right Front Speaker Raffle (Install Foam) Models: 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the right front speaker rattles. Cause The upper trim panel extension, (cover for the exterior mirror fasteners) may be rattling and may be misdiagnosed as a defective speaker. Correction Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 7233 1. Remove the trim panel upper extension. 2. Add a 35 mm (3/8 in) long piece of foam under the lower front corner of the trim panel extension. Place the foam 1.5 mm (1/16 in) from the front edge of the extension and 8.5 mm (3/8 in) up from the bottom edge. Refer to the illustration above. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement Front Door Panel: Service and Repair Armrest Bracket Replacement Armrest Bracket Replacement Removal Procedure 1. Remove the door trim panel. 2. Drill out the rivets (3) which retain the door armrest hanger plate (1). 3. Remove the door armrest hanger plate (1) from the door. Installation Procedure 1. Position the door armrest hanger plate (1) to the door. 2. Install the new rivets (3) to the door hanger plate. 3. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7236 Front Door Panel: Service and Repair Bezel Replacement Door Handle Bezel Replacement Removal Procedure 1. Remove the front door trim panel. 2. Press out the retainer tabs from inside the door trim panel. 3. Remove the bezel (1) from the door. Installation Procedure 1. Position the door handle bezel (1) on the door trim panel. 2. Install the door handle bezel pressing into place until fully seated. 3. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7237 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Removal Procedure A clear waterproof sound deadener deflector is used to seal the door inner panel and prevent entry of water into the body. The deflector is secured to the door inner panel with pressure-sensitive adhesive located on the outboard surface of the deflector. This allows the deflector to be peeled back as needed, to service the door components. 1. Remove the door trim panel. 2. Remove the front door radio speaker (5), if sedan. 3. Remove the armrest bracket (3). 4. Disconnect the power rear view mirror electrical connector, if equipped. 5. Pull the water deflector from the door. Installation Procedure 1. Route the electrical connectors through the existing holes in the water deflector. 2. Install the water deflector to the door inner panel by aligning it to the door. Use a roller around the periphery of the deflector to ensure the proper seating. 3. Install the front door radio speaker (5). 4. Install the armrest bracket (3). 5. Connect the power rear view mirror electrical connector, if equipped. 6. Install waterproof tape to any damaged areas of the deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7238 Front Door Panel: Service and Repair Panel Replacement Front Side Door Trim Panel Replacement (Chevrolet) Front Side Door Trim Panel Replacement (Chevrolet) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the manual window regulator handle from the front door, if equipped. 2. Remove the power door lock switch, if equipped. 3. Remove the upper extension trim panel screw. 4. Remove the upper extension trim panel. 5. Remove the door trim panel screws (3). 6. Remove the armrest screw (1). 7. Starting at the bottom of the door disengage the trim panel retainers using the J 38778. 8. Lift up on the door trim panel (2) to disengage the inner belt molding from the door flange. 9. Remove the door trim panel (2) from the inner door panel. Installation Procedure 1. Position the trim panel (2) to the inner door panel. 2. Engage the inner belt molding over the door flange and press down. 3. Align the door trim panel retainers to the inner door panel. Press the trim panel (2) until the retainers are fully engaged. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7239 4. Install the door trim panel screws (3). Tighten the screws to 1.5 N.m (13 lb in). 5. Install the door armrest screw (1). Tighten the screw to 5.7 N.m (51 lb in). 6. Install the upper extension trim panel. 7. Install the upper extension trim panel screw. Tighten the screw to 1.3 N.m (12 lb in). 8. Install the power door lock switch, if equipped. 9. Install the window regulator handle to the door, if equipped. Trim Panel Replacement - Side Front Door TRIM PANEL REPLACEMENT - SIDE FRONT DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the manual window regulator handle, if equipped. 2. Remove the power door lock switch, if equipped. 3. Remove the upper trim finish panel screw. 4. Remove the upper trim finish panel. 5. Remove the screws (3) from the trim panel (2). 6. Remove the screw (1) from the armrest. 7. Using J 38778 and starting at the door bottom, disengage the door trim panel retainers. 8. Lift up on the door trim panel (2) to disengage the inner belt molding from the door flange. 9. Remove the door trim panel (2) from the door. 10. Disconnect the door speaker electrical connector. INSTALLATION PROCEDURE 1. Position the trim panel (2) to the front door. 2. Connect the door speaker electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7240 3. Engage the inner belt molding over the door flange and press down. 4. Align the door trim panel retainers and press in until the retainers are fully seated. 5. Install the screws (3) to the door trim panel (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). 6. Install the door armrest screws (1). Tighten Tighten the screws to 5.7 N.m (51 lb in). 7. Install the window regulator handle to the door, if equipped. 8. Install the power door lock switch, if equipped. 9. Install the upper trim finish panel. 10. Install the upper trim panel screws. Tighten Tighten the screw to 1.3 N.m (12 lb in). Trim Panel Replacement - Upper Extension Trim Panel Replacement - Upper Extension Removal Procedure 1. Remove upper extension trim panel screw. 2. Remove the trim panel from the inner door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7241 3. If equipped with a manual mirror, slide the trim panel off the mirror handle. 4. Remove the optional power mirror switch. Installation Procedure 1. Install the optional power mirror switch. 2. If the vehicle is equipped with a manual rear view mirror, slide the panel over the mirror handle. 3. Position the upper trim finish panel to the inner door. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper trim panel screw. Tighten the screw to 1.3 N.m (12 lb in). Upper Extension Trim Panel Replacement Upper Extension Trim Panel Replacement Removal Procedure 1. Remove upper extension trim panel screw. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Bracket Replacement > Page 7242 2. Remove the trim panel from the inner door. 3. If equipped with a manual mirror, slide the trim panel off the mirror handle. 4. Remove the optional power mirror switch. Installation Procedure 1. Install the optional power mirror switch. 2. If the vehicle is equipped with a manual rear view mirror, slide the panel over the mirror handle. 3. Position the upper trim finish panel to the inner door. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the upper trim panel screw. Tighten the screw to 1.3 N.m (12 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments 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. 1. Loosen the striker bolts (2). 2. Attach the striker bolts (2) snugly in order to ensure that the striker (1) is still movable. 3. Pull on the outside handle. 4. Gently push the door against the body in order to ensure that the striker (1) allows a flush fit. 5. Slowly open the door. Notice: Refer to Fastener Notice. 6. Tighten the bolts (2). Tighten the striker bolts (2) to 25 N.m (18 lb ft). 7. Touch up any exposed or unpainted surface on the lock pillar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 7246 Front Door Striker: Service and Repair Door Striker Replacement Removal Procedure 1. Remove the striker bolts (2). 2. Remove the washer (4). 3. Remove the spacer (3). 4. Remove the striker (1). Installation Procedure 1. Install the washer (4). 2. Install the spacer (3). 3. Install the striker (1). 4. Align the lock striker. Refer to Door Lock Striker Adjustment. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the striker bolts (2). Tighten the striker bolts (2) to 25 N.m (18 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Auxiliary Sealing Strip Replacement Front Side Door Auxiliary Sealing Strip Replacement Removal Procedure 1. Pull the roof weatherstrip back from the front auxiliary weatherstrip. 2. Remove the bolts (3) from the auxiliary weatherstrip. 3. Using a flat-bladed tool, remove the push-in retainer (2). 4. Remove the auxiliary weatherstrip (1) from the front column. Installation Procedure 1. Position the auxiliary weatherstrip (1) on the front column. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front auxiliary weatherstrip bolts (3). Tighten the front auxiliary weatherstrip bolts to 2 N.m (18 lb in). 3. Install the push-in retainer (2) pressing in until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement > Page 7251 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Coupe) Front Door Opening Weatherstrip Replacement (Coupe) Removal Procedure 1. Remove the carpet retainer from the vehicle. 2. Remove the windshield garnish molding. 3. Loosen the quarter trim panel. Refer to Rear Quarter Trim Panel Replacement in Interior Trim. 4. Pull the front door opening weatherstrip (1) loose and remove it from the vehicle. Installation Procedure 1. Apply weather-strip adhesive GM P/N 12345096 (Canadian P/N 993365) or equivalent, to the front door opening weatherstrip (1). 2. Install the front door opening weather-strip (1) onto the front door pinch weld, pressing into place until fully seated. 3. Install the windshield garnish molding. 4. Install the quarter trim panel. 5. Install the carpet retainer to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement > Page 7252 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Sedan) Front Door Opening Weatherstrip Replacement (Sedan) Removal Procedure 1. Remove the carpet retainer from the vehicle. 2. Remove the windshield garnish molding. 3. Remove the center pillar trim. 4. Pull the front door opening weatherstrip (1) loose and remove it from the vehicle. Installation Procedure 1. Apply weatherstrip adhesive GM P/N 12345096, or equivalent, to the front door opening weatherstrip (1). 2. Install the front door opening weatherstrip (1) onto the front door pinch weld, pressing into place until fully seated. 3. Install the windshield garnish molding. 4. Install the center pillar trim. 5. Install the carpet retainer to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Door Window Channel Replacement Door Window Channel Replacement Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door rear view mirror. 5. Remove the sealing strip, window belt outer. 6. Remove the channel (2) lower bolt (3). 7. Remove the push-in retainer (1) at the top of the channel. 8. Remove the window run channel weather-strip from the front door window (4). Installation Procedure 1. Install the run channel weather-strip (2) to the front door window. 2. Install the push-in retainer (1) at the top of the channel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the channel lower bolt (3). Tighten the upper window channel lower bolt to 6 N.m (53 lb in). 4. Install the sealing strip, window belt outer. 5. Install the front door rear view mirror. 6. Install the front door window. 7. Install the front door water deflector. 8. Install the front door trim panel. Front Side Door Window Rear Channel Replacement Front Side Door Window Rear Channel Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 7258 Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door reveal molding by the window rear channel. 5. Remove the bolt from the rear channel (2). 6. Lift up the rear channel to disengage the top clip. 7. Remove the window rear channel (1) from the front door. Installation Procedure 1. Position the rear run channel (1) in the front door. 2. Lift up the rear channel to install the top clip. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the window rear channel bolt (2). Tighten the lower window channel bolt 6 N.m (53 lb in). 4. Install the reveal molding. 5. Install the front door window. 6. Install the front door water deflector. 7. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 7259 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (1) from the door sealing strip. 3. Remove the door sealing strip (2). Installation Procedure 1. Install the door sealing strip (2). 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (1) to the door sealing strip. Tighten the door sealing strip screw (1) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Power) Front Side Door Window Regulator Replacement (Power Regulator) Removal Procedure 1. Lower the window to the three quarters down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts (4). 5. Push the window to the closed position and tape in place. 6. Disconnect the regulator electrical connector. 7. Remove the power window regulator bolts (3). 8. Drill out the power window regulator rivets (2). 9. Remove the power window regulator (5) from the door. Installation Procedure 1. Position the power window regulator (5) in the door. 2. Connect the door window regulator electrical connector. 3. Install the power window regulator rivets (2). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power window regulator bolts (3). Tighten the regulator bolts (3) to 10 N.m (89 lb in). 5. Remove the tape from the window and push the window down to the regulator. 6. Install the power window to regulator nuts (4). Tighten the window to regulator nuts (4) to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 7264 7. Install the water deflector. 8. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 7265 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Front Side Door Window Regulator Replacement (Manual Regulator) Removal Procedure 1. Position the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the regulator to window nuts. 5. Push the window to the closed position and tape in place. 6. Remove the manual window regulator bolts (3). 7. Remove the manual window regulator rivets (2). 8. Remove the manual window regulator (5) from the door. Installation Procedure 1. Position the manual window regulator (5) in the door. 2. Install the manual window regulator rivets (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator bolts (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 7266 Tighten the regulator bolts (3) to 10 N.m (89 lb in). 4. Remove the tape from the window and push it down to the regulator. 5. Install the manual window regulator nuts (4). Tighten the regulator nuts (4) to 10 N.m (89 lb in). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement Removal Procedure Important: This procedure is completed with the rear door closed at all times. Do each door hinge separately, and replace the broken door hinge first. 1. Open the front door in order to remove the rear door hinges. 2. Clean the mounting surfaces with clean a rag and mark the rear door hinge locations on each surface with a grease pencil or other suitable marker. 3. Remove the bolts from the door side rear door hinge. 4. Remove the bolts (1-5) from the body side rear door hinge. 5. Remove the rear door hinge from the vehicle. Installation Procedure 1. Position the rear door hinge to the alignment marks. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1-5) to the body side rear door hinge. Tighten the body side rear door hinge bolts to 33 N.m (24 lb ft). 3. Install the bolts to the door side rear door hinge. Tighten the door side rear door hinge bolts to 33 N.m (24 lb ft). 4. Close the rear door. 5. Inspect the rear door for proper operation and alignment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Rear Side Door Trim Panel Replacement TRIM PANEL REPLACEMENT - SIDE REAR DOOR TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the power window switch, if equipped. 2. Remove the window manual regulator handle, if equipped. 3. Remove the armrest screws (1). 4. Remove the lower trim panel screws. 5. Using J 38778 and starting at the door bottom, disengage the door trim panel (2) retainers. 6. Remove the door trim panel (2) from the door by lifting up on the panel to disengage the inner belt weatherstrip. INSTALLATION PROCEDURE 1. Position the rear door trim panel (2) to the door, pressing down to seat the inner belt weatherstrip. 2. Align the push-in retainers and push in to engage the retainers. 3. Install the door armrest bolt (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 5.7 N.m (51 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 7275 4. Install the lower door trim screws. Tighten Tighten the screws to 1.5 N.m (13 lb in). 5. Install the window regulator handle, if equipped. 6. Install the power window switch, if equipped. Rear Side Door Trim Panel Replacement (Chevrolet) Rear Side Door Trim Panel Replacement (Chevrolet) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the power window switch, if equipped. 2. Remove the window manual regulator handle, if equipped. 3. Remove the armrest screws (1). 4. Remove the lower trim panel screws. 5. Using J 38778 and starting at the door bottom, disengage the door trim panel (2) retainers. 6. Remove the door trim panel (2) from the door by lifting up on the panel to disengage the inner belt weatherstrip. Installation Procedure 1. Position the rear door trim panel (2) to the door, pressing down to seat the inner belt weatherstrip. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 7276 2. Align the push-in retainers and push in to engage the retainers. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the door armrest bolt (1). Tighten the screws to 5.7 N.m (51 lb in). 4. Install the lower door trim screws. Tighten the screws to 1.5 N.m (13 lb in). 5. Install the window regulator handle, if equipped. 6. Install the power window switch, if equipped. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 7277 Rear Door Panel: Service and Repair Energy Absorber Pad Replacement 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. Open the door. 2. Remove the door trim panel. 3. Remove the bolts (2) from the energy absorber pad. 4. Remove the energy absorber from the door. Installation Procedure 1. Position the rear door energy absorber (1) in the door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) to the energy absorber pad. Tighten the rear door energy absorber bolts to 2 N.m (18 lb in). 3. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 7278 Rear Door Panel: Service and Repair Water Deflector Rear Side Door Water Deflector Replacement Removal Procedure 1. Remove the rear door trim panel. 2. Remove the armrest bracket (4). 3. Remove the rear door water deflector (3), starting at the top, pull downward (1). 4. Route the electrical connectors through the existing holes in the water deflector. Installation Procedure 1. Route the electrical connectors through the water deflector (3). 2. Install the water deflector to the door inner panel by aligning it to the door. Use a roller around the periphery of the deflector to ensure proper seating. 3. Install the armrest bracket (4). 4. Install the rear door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments 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. 1. Loosen the striker bolts (2). 2. Attach the striker bolts (2) snugly in order to ensure that the striker (1) is still movable. 3. Pull on the outside handle. 4. Gently push the door against the body in order to ensure that the striker (1) allows a flush fit. 5. Slowly open the door. Notice: Refer to Fastener Notice. 6. Tighten the bolts (2). Tighten the striker bolts (2) to 25 N.m (18 lb ft). 7. Touch up any exposed or unpainted surface on the lock pillar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 7282 Rear Door Striker: Service and Repair Door Striker Replacement Removal Procedure 1. Remove the striker bolts (2). 2. Remove the washer (4). 3. Remove the spacer (3). 4. Remove the striker (1). Installation Procedure 1. Install the washer (4). 2. Install the spacer (3). 3. Install the striker (1). 4. Align the lock striker. Refer to Door Lock Striker Adjustment. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the striker bolts (2). Tighten the striker bolts (2) to 25 N.m (18 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Remove the carpet retainer. 2. Remove the upper center pillar trim panel from the vehicle. 3. Remove the rear lower quarter trim panel. 4. Remove the rear upper quarter trim panel. 5. Pull the rear door opening weatherstrip (2) loose. 6. Remove the weatherstrip (2) from the vehicle. Installation Procedure 1. Apply weatherstrip (2) adhesive GM P/N 12345096 (Canadian P/N 993365) or equivalent, to the rear door opening weatherstrip. 2. Press the rear door opening weather-strip (2) onto the rear door opening flange. 3. Install the carpet retainer. 4. Install the upper center pillar trim panel in the vehicle. 5. Install the rear lower quarter trim panel. 6. Install the rear upper quarter trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 7287 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement Rear Side Door Front Auxiliary Weatherstrip Replacement Removal Procedure 1. Use a flat-bladed tool in order to disengage the push-pin retainers (1). 2. Remove the center column auxiliary weatherstrip from the vehicle. Installation Procedure 1. Position the auxiliary weatherstrip on the center column. 2. Firmly press in the push-in retainers (1) making sure they are all seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 7288 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Rear Side Door Bottom Auxiliary Sealing Strip Replacement Removal Procedure 1. Remove the screws (2) from the rear door lower sealing strip. 2. Remove the rear door lower sealing strip (1) from the quarter panel. Installation Procedure 1. Position the rear door lower sealing strip (1) on the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws (2) to the rear door lower sealing strip. Tighten the door sealing strip screws to 2 N.m (13 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Front Channel Replacement Removal Procedure 1. Ensure that the window is fully closed. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the window regulator. 5. Lower the window to the bottom of the door. 6. Remove the lower bolt (2). 7. Lift the channel to disconnect the upper fastener. 8. Remove the front window channel (1) from the door. Installation Procedure 1. Position the front window channel (1) in the door, top end first. 2. Insert the channel top retainer into the slot. 3. Rotate the top of the front window channel rearward and align it on the lower edge of the window. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear door window channel lower bolt (2). Tighten the lower window channel bolt to 6 N.m (53 lb in). 5. Lift up the window and install the window regulator. 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 7294 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Side Door Window Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (3) from the door sealing strip. 3. Lift up to remove the door sealing strip (2) from the door. Installation Procedure 1. Position the door sealing strip (2) to the door. 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (3) to the door sealing strip. Tighten the door sealing strip screw (3) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Manual Rear Side Door Window Regulator Replacement (Manual Regulator) Removal Procedure 1. Lower the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts. 5. Push the window up to the full closed position and tape in place. 6. Drill out the manual window regulator rivets (3). 7. Remove the power window regulator nuts (2). 8. Remove the manual window regulator (1) from the door. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 7299 1. Position the manual window regulator (1) in the door. 2. Install the manual window regulator rivets (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator nuts (2). Tighten the regulator nuts (2) to 10 N.m (89 lb in). 4. Remove the tape from the window and push it down to the regulator. 5. Install the power window to regulator nuts (2). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 7300 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Power Rear Side Door Window Regulator Replacement (Power Regulator) Removal Procedure 1. Lower the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts. 5. Push the window up to the full closed position and tape in place. 6. Drill out the power window regulator rivets (3). 7. Remove the power window regulator nuts (2). 8. Remove the electrical connector. 9. Remove the power window regulator (1) from the door. Installation Procedure 1. Position the power window regulator (1) in the door. 2. Install the power window regulator rivets (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power window regulator nuts (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 7301 Tighten the regulator nuts (2) to 10 N.m (89 lb in). 4. Remove the tape from the window and push the window down to the regulator. 5. Install the power window to regulator nuts (2). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures Fuel Door: Procedures Fuel Filler Pocket Replacement FUEL FILLER POCKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the screws (2) from the fuel tank filler pocket. 2. Remove the gas cap. 3. Remove the fuel tank filler pocket (1). INSTALLATION PROCEDURE 1. Install the fuel tank filler pocket (1). 2. Install the bolts (2) to the fuel tank filler pocket. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 2 N.m (18 lb in). 3. Install the gas cap. Fuel Filler Door Replacement FUEL FILLER DOOR REPLACEMENT REMOVAL PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 7306 1. Remove the nuts (2) from the fuel tank filler door. 2. Remove the fuel tank filler door (1). 3. Remove the gas cap connector. INSTALLATION PROCEDURE 1. Install the filler door gas cap connector. 2. Install the fuel tank filler door. 3. Install the nuts (2) to the filler door (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fuel tank filler door nuts to 2.8 N.m (24.8 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 7307 Fuel Door: Removal and Replacement Fuel Tank Filler Door Replacement Fuel Tank Filler Door Replacement Removal Procedure 1. Remove the nuts (2) from the fuel tank filler door. 2. Remove the fuel tank filler door (1). 3. Remove the gas cap connector. Installation Procedure 1. Install the filler door gas cap connector. 2. Install the fuel tank filler door. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts (2) to the filler door (1). Tighten the fuel tank filler door nuts to 2.8 N.m (24.8 lb in). Fuel Tank Filler Pipe Housing Replacement Fuel Tank Filler Pipe Housing Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Procedures > Page 7308 1. Remove the screws (2) from the fuel tank filler pocket. 2. Remove the gas cap. 3. Remove the fuel tank filler pocket (1). Installation Procedure 1. Install the fuel tank filler pocket (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (2) to the fuel tank filler pocket. Tighten the bolts to 2 N.m (18 lb in). 3. Install the gas cap. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure 1. Remove the hood. 2. Using a grease pencil, mark the position of the hood hinge to the fender. 3. Remove the hinge to fender bolts. 4. Remove the hinge from the vehicle. Installation Procedure 1. Position the hood hinge to the alignment marks on the fender. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hood hinge to fender bolts. Tighten the hood hinge bolts to 20 N.m (15 lb ft). 3. Install the hood. 4. Align the hood if necessary. Refer to Hood Adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Use the J 38778 to remove the hood insulator push-in retainers from the hood. 3. Remove the hood insulator from the hood. Installation Procedure 1. Position the hood insulator to the hood. 2. Install the hood insulator push-in retainers until fully seated. 3. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support 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. Remove the hood close out filler panel. 1. Remove the hood latch cover. 2. Remove the hood latch. 3. Disable the air bag sensor. Refer to SIR Disabling and Enabling 4. Remove the lower bolts (4) from the lower hood latch support. 5. Remove the upper bolts (2) from the hood latch support. 6. Remove the hood latch support (1) from the vehicle. Installation Procedure 1. Position the hood latch support (1) in the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 7320 2. Install the lower bolts (4) to the hood latch support. Tighten the hood latch support lower bolts to 27 N.m (20 lb ft). 3. Install the upper bolts (2) to the hood latch support. Tighten the hood latch support upper bolts to 9 N.m (80 lb in). 4. Install the hood latch. 5. Engage the air bag sensor. Refer to SIR Disabling and Enabling 6. Install the hood latch cover. 7. Install the hood close out filler panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 7321 Hood Latch: Service and Repair Hood Latch Cover Replacement Hood Latch Cover Replacement Removal Procedure 1. If Sunfire, remove the hood close out filler panel. 2. Remove the hood latch cover retainers (2). 3. Remove the hood latch cover (1). Installation Procedure 1. Install the hood latch cover (1). 2. Install the hood latch cover retainers (2). 3. If Sunfire, install the hood close out filler panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 7322 Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Hood Primary and Secondary Latch Replacement Removal Procedure 1. Open the hood. 2. Mark the hood latch location to the support bracket with a grease pencil. 3. Remove the hood latch bolts (2). 4. Disconnect the hood latch release cable (3) from the hood latch (1) by squeezing the cable retainer. 5. Remove the hood latch (1) from the vehicle. Installation Procedure 1. Install the hood latch release cable (3) to the hood latch (1). 2. Position the hood latch (1) to the alignment marks on the support bracket. 3. Install the hood latch bolts (2). 4. Tighten the latch bolts with the latch in the full up position. Notice: Refer to Fastener Notice in Service Precautions. 5. Slowly close the hood and press down until the hood is flush with the fenders. Open the hood and tighten the hood latch bolts to 10 N.m (89 lb ft). 6. Adjust the hood, if required. Refer to Hood Adjustment. 7. Close the hood Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Support Replacement > Page 7323 Hood Latch: Service and Repair Hood Primary Latch Striker Replacement Hood Primary Latch Striker Replacement Removal Procedure 1. Open the hood. 2. Mark the location of the hood latch striker on the hood. 3. Remove the hood latch striker bolts (2) from the hood. 4. Remove the hood latch striker (1) from the hood. Installation Procedure 1. Position the hood latch striker (1) to the hood to the marks on the hood. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hood latch striker bolts (2) to the hood. Tighten the bolts to 25 N.m (18 lb ft). 3. Adjust the hood latch striker if necessary. 4. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Removal Procedure 1. Open the hood. 2. Block the hood latch to prevent the hood from locking. 3. Disconnect the hood release cable from the hood latch by squeezing the hood release cable retainer. 4. Remove the side trim panel retainers. 5. Remove the hood latch release cable screws. 6. Remove the hood latch release cable handle from the front hinge pillar. Important: Ensure the end of the wire or string remains in the passenger compartment. 7. Tie the wire or string to the end of the hood release cable in order to aid in the installation of the new hood release cable. 8. Remove the grommet from the engine compartment into the passenger compartment using a small flat-bladed tool. Clean the old sealant from instrument panel hole. 9. Remove the hood release cable from the instrument panel. 10. Remove the wire or string from the hood release cable. 11. Remove the hood latch release cable (1). Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 7327 1. Tie the wire or string to the hood release cable. 2. Install the hood primary latch release cable through the hole in the instrument panel. 3. Install the hood release cable through the instrument panel using a small flat-bladed tool until the grommet is fully seated. 4. Remove the wire or string from the hood release cable. 5. Install the hood latch release cable ball to the latch. 6. Install the hood latch release cable handle to the hinge pillar. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the hood latch release cable screws. Tighten the hood latch release cable handle screws to 3 N.m (27 lb in). 8. Install the side trim panel retainers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Hood Hold-Open 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. Open and support the hood. 2. Remove the support from the hood rod retaining clip (1). 3. Use a small, flat-bladed tool to lift up the retainer clip (1). 4. Use a small, flat-bladed tool to remove the hood hold open rod (2), by prying outward. 5. Remove the hood hold open rod retainer bushing by pulling outward. Installation Procedure 1. Position the hood hold open rod retainer to the radiator support. Press in until fully seated. 2. Push the hood hold open rod (2) into the retainer until fully seated. 3. Install the retainer clip (1). 4. Position the rod in the clip (1). 5. Remove the hood support. 6. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Side Bumper Replacement Removal Procedure 1. Open the hood. 2. Remove the hood side bumper (1) from the fender by sliding the bumper rearward. Installation Procedure 1. Install the hood side bumper (1) to the fender by sliding the bumper forward. 2. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Plenum to Hood Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Pull the hood rear seal (1) from the pinch weld. Installation Procedure 1. Position the hood rear seal to the vehicle. 2. Push the hood rear seal (1) into the pinch weld in order to fully seat the seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Plenum to Hood > Page 7338 Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement Hood Rear Outer Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal, located at the end of the plenum to hood seal, from the fender. 3. Remove the seal from the vehicle. 4. Clean any adhesive from the pinch-weld flange and hood hinge using 3M(TM) P/N 8984. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. With the rear side hood seal butted to the plenum to hood seal, press the side hood seal until the adhesive is fully adhered. 3. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Rear Compartment Lid Release Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 7343 Rear Compartment Lid Release Actuator Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair Rear Compartment Lid Hinge Replacement Removal Procedure 1. Remove the compartment lid. 2. Remove the wire harness rosebuds from the hinge arm. 3. Remove the compartment lid torque rods. 4. Remove the rear panel window trim. 5. Remove the compartment lid hinge bolts (3). 6. Remove the compartment lid hinge (4). Installation Procedure 1. Install the compartment lid hinge (4). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hinge bolts (3) to the rear window panel. Tighten the rear compartment hinge to rear window panel bolt to 10 N.m (89 lb in). 3. Install the rear panel window trim. 4. Install the compartment lid torque rods. 5. Install the compartment lid. 6. Install the wire harness rosebuds to the hinge arm. 7. Adjust the compartment lid. Refer to Rear Compartment Lid Adjustment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Rear Compartment Lid Latch Replacement Removal Procedure 1. With a grease pencil, mark the location of the latch on the compartment lid. 2. Remove the lock cable assembly (8). 3. Unclip the cable door at the top of the lock release box (2) to expose the remote release cable, if equipped. 4. Remove the remote release cable (1) from the lock release box, if equipped. 5. Remove the latch cable assembly bolts (7). 6. Remove the latch assembly (3). Installation Procedure 1. Position the latch assembly (3) to the alignment marks. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the latch assembly bolts (7). Tighten the rear compartment lid latch assembly bolts to 6 N.m (53 lb in). 3. Install the remote release cable (1) to the lock release box, if equipped. 4. Clip the cable door at the top of the lock release box (2), if equipped. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Page 7350 5. Install the lock cable assembly (8). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Rear Compartment Lid Lock Cylinder Replacement Removal Procedure 1. Remove the compartment lid applique. 2. Remove the compartment lid latch cable assembly (8) from behind the lid lock. Spread the black plastic housing and pull down. 3. For the Cavalier only, remove the compartment lid lock cylinder retainer (4). 4. For the Sunfire only, drill out the rivets. 5. Remove the compartment lid lock cylinder (1). Installation Procedure 1. Install the compartment lid lock cylinder (1). 2. For the Cavalier only, install the compartment lid lock cylinder retainer (4). 3. For the Sunfire only, install the spacer and the lock rivets. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair > Page 7354 4. Install the compartment lid lock cable assembly (8). 5. Install the compartment lid applique. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Rear Compartment Lid Hinge Torque Rod Replacement Trunk / Liftgate Shock / Support: Service and Repair Rear Compartment Lid Hinge Torque Rod Replacement Rear Compartment Lid Hinge Torque Rod Replacement Tools Required * J 39384-10Torsion Rod Adjustment Bar * J 39719Trunk Deck Lid Torsion Rod Adjuster 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. Prop the compartment lid (2) in the full-open position. 2. Use the J 39719, the J 39384-10 or the equivalent (6) in order to remove the torque rod (5) from the adjusting notch. 3. With the torque rod removed from the adjuster notch, push the rod out of the hinge arm. 4. Remove the torque rod (1) from the rear compartment lid hinge (4). Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Rear Compartment Lid Hinge Torque Rod Replacement > Page 7359 1. Install the torque rod to the compartment lid hinge arm(4). 2. Use the J 39719, the J 39384-10 or the equivalent (6) in order to engage the torque rod (5) to the adjusting notch. 3. Adjust the operating effort by adjusting the rear compartment torque rods. Use the following procedure: 1. Reposition the end of the torque rod (5) to a lower adjusting notch in order to obtain the following results: * Increase the amount of effort needed in order to raise the compartment lid. * Decrease the amount of effort needed in order to close the compartment lid. 2. Reposition the end of the torque rod (5) to a higher adjusting notch in order to obtain the following results: * Decrease the amount of effort needed in order to raise the compartment lid. * Increase the amount of effort needed in order to close the compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Rear Compartment Lid Hinge Torque Rod Replacement > Page 7360 Trunk / Liftgate Shock / Support: Service and Repair Torque Rod Replacement - Rear Compartment Lid Torque Rod Replacement - Rear Compartment Lid Tools Required * J 39384-10Torsion Rod Adjustment Bar * J 39719Trunk Deck Lid Torsion Rod Adjuster 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. Prop the compartment lid (2) in the full-open position. 2. Use the J 39719, the J 39384-10 or the equivalent (6) in order to remove the torque rod (5) from the adjusting notch. 3. With the torque rod removed from the adjuster notch, push the rod out of the hinge arm. 4. Remove the torque rod (1) from the rear compartment lid hinge (4). Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Rear Compartment Lid Hinge Torque Rod Replacement > Page 7361 1. Install the torque rod to the compartment lid hinge arm(4). 2. Use the J 39719, the J 39384-10 or the equivalent (6) in order to engage the torque rod (5) to the adjusting notch. 3. Adjust the operating effort by adjusting the rear compartment torque rods. Use the following procedure: 1. Reposition the end of the torque rod (5) to a lower adjusting notch in order to obtain the following results: * Increase the amount of effort needed in order to raise the compartment lid. * Decrease the amount of effort needed in order to close the compartment lid. 2. Reposition the end of the torque rod (5) to a higher adjusting notch in order to obtain the following results: * Decrease the amount of effort needed in order to raise the compartment lid. * Increase the amount of effort needed in order to close the compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Stop > Component Information > Service and Repair > Rear Compartment Lid Overslam Bumper Replacement Trunk / Liftgate Stop: Service and Repair Rear Compartment Lid Overslam Bumper Replacement Rear Compartment Lid Overslam Bumper Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment lid outer bumper (1) by unscrewing counterclockwise. Installation Procedure 1. Install the rear compartment lid outer bumper (1) by rotating the bumper until the lid is flush with the rear quarter. 2. Close the rear compartment. 3. Inspect the lid for proper fit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Stop > Component Information > Service and Repair > Rear Compartment Lid Overslam Bumper Replacement > Page 7366 Trunk / Liftgate Stop: Service and Repair Overslam Bumper Replacement - Rear Compartment Lid Overslam Bumper Replacement - Rear Compartment Lid Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment lid outer bumper (1) by unscrewing counterclockwise. Installation Procedure 1. Install the rear compartment lid outer bumper (1) by rotating the bumper until the lid is flush with the rear quarter. 2. Close the rear compartment. 3. Inspect the lid for proper fit. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Lock Striker Replacement - Rear Compartment Lid Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Rear Compartment Lid Lock Striker Replacement - Rear Compartment Lid Removal Procedure 1. Remove the rear compartment sill plate. 2. Pull back the rear compartment trim panel and with a grease pencil, mark the location of the lock striker. 3. Remove the lock striker nuts (3). 4. Remove the lock striker reinforcement plate (2). 5. Remove the lock striker (1) from the rear compartment. Installation Procedure 1. Position the lock striker (1) to the alignment marks. 2. Install the lock striker reinforcement plate (2). 3. Install and hand tighten the striker nuts (3). 4. Slowly close the compartment lid and check the striker alignment. Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the lock striker nuts (3). Tighten the rear compartment lid lock striker nuts to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Lock Striker Replacement - Rear Compartment Lid > Page 7371 Trunk / Liftgate Striker: Service and Repair Rear Compartment Lid Latch Striker Replacement Rear Compartment Lid Latch Striker Replacement Removal Procedure 1. Remove the rear compartment sill plate. 2. Pull back the rear compartment trim panel and with a grease pencil, mark the location of the lock striker. 3. Remove the lock striker nuts (3). 4. Remove the lock striker reinforcement plate (2). 5. Remove the lock striker (1) from the rear compartment. Installation Procedure 1. Position the lock striker (1) to the alignment marks. 2. Install the lock striker reinforcement plate (2). 3. Install and hand tighten the striker nuts (3). 4. Slowly close the compartment lid and check the striker alignment. Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the lock striker nuts (3). Tighten the rear compartment lid lock striker nuts to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 7375 Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 7376 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool to release the retaining tabs for the rear compartment lid switch. Remove the switch from the Instrument Panel (IP) carrier. 2. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the switch to the IP carrier. Press the switch until the retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Removal Procedure 1. Peel the weatherstrip from the pinch weld flange. Move the weatherstrip in the following direction: 1. Toward the lower corners 2. Around the complete opening 2. Clean all of the adhesive from the pinch-weld flange. Installation Procedure 1. Apply a bead of weatherstrip adhesive GM P/N 12345096 to the following areas: 1. The edge of the pinch-weld flange 2. Around the entire perimeter of the rear compartment opening 2. Install the center of the weatherstrip onto the gutter flange. Begin at the forward center of the opening between the hinge arms. 3. Push down by hand on the weatherstrip over the entire area until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Adhesive Installation of Stationary Windows. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-66-010 > Jul > 04 > Body - Deck Lid Emblem Discolored Body Emblem: Customer Interest Body - Deck Lid Emblem Discolored Bulletin No.: 04-08-66-010 Date: July 20, 2004 TECHNICAL Subject: Bowtie Emblem Discoloration (Replace The Emblem) Models: 2004 Chevrolet Cavalier Condition Some customers may comment that the emblem on the deck lid is discolored. Cause This concern may be due to cleaning solvent that contains the following chemicals used to clean bug and debris off the vehicle: ^ Oxalic Acid ^ Dihydrate Techorganic Acid ^ Hydroflorides Correction Replace the emblem. DO NOT replace the applique. 1. Place a piece of tape next to the emblem to prevent damage to the applique. 2. Use a plastic trim tool and remove the emblem from the applique as seen in the illustration. Use 3M(R) General Purpose Adhesive Cleaner, or equivalent, to help release the emblem. 3. Clean the applique with 3M(R) General Purpose Adhesive Cleaner, or equivalent. 4. Install the new emblem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-66-010 > Jul > 04 > Body - Deck Lid Emblem Discolored > Page 7392 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Emblem: > 06-08-111-004B > Sep > 09 > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: All Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Emblem: > 04-08-66-010 > Jul > 04 > Body - Deck Lid Emblem Discolored Body Emblem: All Technical Service Bulletins Body - Deck Lid Emblem Discolored Bulletin No.: 04-08-66-010 Date: July 20, 2004 TECHNICAL Subject: Bowtie Emblem Discoloration (Replace The Emblem) Models: 2004 Chevrolet Cavalier Condition Some customers may comment that the emblem on the deck lid is discolored. Cause This concern may be due to cleaning solvent that contains the following chemicals used to clean bug and debris off the vehicle: ^ Oxalic Acid ^ Dihydrate Techorganic Acid ^ Hydroflorides Correction Replace the emblem. DO NOT replace the applique. 1. Place a piece of tape next to the emblem to prevent damage to the applique. 2. Use a plastic trim tool and remove the emblem from the applique as seen in the illustration. Use 3M(R) General Purpose Adhesive Cleaner, or equivalent, to help release the emblem. 3. Clean the applique with 3M(R) General Purpose Adhesive Cleaner, or equivalent. 4. Install the new emblem. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Emblem: > 04-08-66-010 > Jul > 04 > Body - Deck Lid Emblem Discolored > Page 7402 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Emblem: > 06-08-111-004B > Sep > 09 > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: All Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures Body Emblem: Procedures Compartment Lid Applique Replacement COMPARTMENT LID APPLIQUE REPLACEMENT - REAR (PONTIAC SEDAN/CHEVROLET ALL) REMOVAL PROCEDURE 1. Disconnect the wire harness sockets from the back-up light. 2. Remove the nuts (1) from the rear compartment lid applique. 3. Remove the lid applique (5) from the rear compartment. INSTALLATION PROCEDURE 1. Install the lid applique (5) to the rear compartment. 2. Install the nuts (1) to the rear compartment lid applique. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 5 N.m (44 lb in). 3. Connect the wire harness sockets to the back-up light assemblies. Emblem/Nameplate Repair Emblem/Nameplate Repair Notice: Use of harsh chemicals when cleaning can damage exterior lamps. Suggested cleaners are a mild soap and water, or Varnish Makers and Painters (VM&P;) Naptha. VM&P; Naptha is a specific type of naptha and should not be substituted by any other naptha. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7410 1. Wash the panel using soap and water. 2. Wipe the panel dry. 3. Use a clean rag and 3M General Purpose Adhesive Cleaner 08984 or the equivalent in order to wipe the panel and the adhesive side of the the emblem/nameplate (2). 4. Use a clean rag and an alcohol/water mixture in order to remove residue from the following components: * The molding * The emblem * The nameplate Notice: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with Adhesive Cleaner. Wipe the tape and mating surface with a clean, soft cloth. If the tape is damaged, refer to Emblem/Nameplate Replacement. 5. Apply a length of masking tape or a magnetic strip as a guide, if needed. Important: Use the minimum amount of adhesive required. Adhesive drips or squeeze-out may cause paint damage. 6. Apply a thin film of adhesive to the back of the emblem/nameplate (2). * The molding * The emblem * The nameplate 7. Press the piece into place. If you use the LOCTITE(TM) 414 adhesive GM P/N 1052621 (Canadian P/N 993365) or the equivalent, apply constant pressure to the molding for 30 seconds or until a firm bond has been made. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7411 Body Emblem: Removal and Replacement Front Bumper Fascia Emblem Replacement Front Bumper Fascia Emblem Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using J 25070. Hold the J 25070 approximately 152 mm (6 in) from the surface. 3. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to lift or remove the emblem/nameplate from the panel surface. Important: If tape is still intact on the molding or panel, do not remove the tape. Clean the tape and the mating surface with adhesive cleaner. Wipe the tape and the mating surface with a clean, lint free cloth. If the tape is damaged, continue with the replacement procedure. 5. Apply the adhesive foam tape to the back of the emblem/nameplate and press the emblem/nameplate in place. 6. When replacing, remove all adhesive as follows: * For body panels, use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels, use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7412 Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of isopropyl alcohol and water to clean the area. 2. Dry the area thoroughly. 3. Use a J 25070 to heat the mounting surface to approximately 27-41°C (80-105°F), if necessary. 4. Hold the J 25070 heat gun approximately 152 mm (6 in) from the surface. 5. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/nameplate. 7. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting surface. 8. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Front Side Door Emblem/Nameplate Replacement Front Side Door Emblem/Nameplate Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. When replacing an emblem/nameplate, do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070. 3. Apply the heat using a circular motion for about 30 seconds holding the J 25070 approximately 152 mm (6 in) from the surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7413 Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When replacing, remove all adhesive as follows: * For body panels, use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels, use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a, 50/50 mixture, by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a, 50/50 mixture, by volume of isopropyl alcohol and water to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape and use the following dimensions: 4. For the SUNFIRE emblem/nameplate, install to the following dimensions: * Dimension (a) is 57 mm (2.250 in) from the front edge of the door to the front of the emblem/nameplate. * Dimension (b) is 39 mm (1.500 in) from the top of the door molding to the bottom of the emblem/nameplate. 5. For the SUNFIRE GT emblem/nameplate, install to the following dimensions: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7414 * Dimension (a) is 57 mm (2.250 in) from the front edge of the door to the front of the emblem/nameplate. * Dimension (b) is 26 mm (1.024 in) between the SUNFIRE and the GT emblem/nameplate. * Dimension (c) is 39 mm (1.535 in) from the top of the door molding to the bottom of the emblem/nameplate. 6. Heat the mounting surface to approximately 27-41°C (80-105°F) using the J 25070, if necessary. 7. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing on the emblem/nameplate. 8. Remove the protective liner from the back of the emblem/nameplate. 9. Position the emblem/name plate to the location marks and press the emblem/nameplate to the mounting surface. 10. Apply equal pressure along the emblem/name plate to uniformly bond the item to the mounting surface. 11. Remove the protective tape from the mounting surface. Rear Compartment Lid Emblem/Nameplate Replacement Rear Compartment Lid Emblem/Nameplate Replacement Tools Required J 25070 Heat Gun Removal Procedure 1. When replacing an emblem/nameplate, do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070. 3. Apply the heat using a circular motion for about 30 seconds holding the J 25070 approximately 152 mm (6 in) from the surface. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When replacing, remove all adhesive as follows: * For body panels, use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels, use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a, 50/50 mixture, by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a, 50/50 mixture, by volume of isopropyl alcohol and water to clean the area. 2. Dry the area thoroughly. 3. If the location of the emblem/nameplate has not been marked, apply tape. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Procedures > Page 7415 4. Install the Cavalier LS emblem/nameplate to the following dimensions: * Dimension (a) is 43 mm (1.688 in) from the left edge of the rear compartment lid to the nameplate. * Dimension (b) is 45 mm (1.750 in) from the bottom edge of the rear compartment lid to the nameplate. * Dimension (c) is 235 mm (9.250 in) from the left edge of the rear compartment lid to the LS nameplate. * Dimension (d) is 45 mm (1.750 in) from the bottom edge of the rear compartment lid to the nameplate. 5. Heat the mounting surface to approximately 27-41°C (80-105°F) using the J 25070, if necessary. 6. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing on the emblem/nameplate. 7. Remove the protective liner from the back of the emblem/name plate. 8. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting surface. 9. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 10. Remove the protective tape from the mounting surface. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arm assemblies. 3. Disconnect the washer tubing from the air inlet screen. 4. Using J 38778, remove the air inlet grille panel push-in retainers (1) from the panel. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Install the air inlet grille panel push-in retainers (1) to the panel. 3. Connect the washer tubing to the air inlet panel. 4. Install the wiper arms and blade assemblies. 5. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 7423 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 7424 Windshield Moulding / Trim: Service and Repair Windshield Reveal Molding Replacement Windshield Reveal Molding Replacement The windshield reveal molding is an applied molding design separate from the window. The reveal molding is bonded to the windshield and may be bonded to the body. The reveal molding may be replaced with the windshield as an assembly, or the reveal molding may be available as a separate service part. Refer to Adhesive Installation of Stationary Windows. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Fender Liner Replacement Removal Procedure 1. Raise and support the vehicle.Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the screws from the front fender liner at the front bumper fascia. 4. Remove the push-in retainers from the fender liner. 5. Remove the screws from the fender liner to the fender. 6. Remove the front fender liner (3) from the fender. Installation Procedure 1. Position the fender liner (3) to the front fender. 2. Install the push-in retainers. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws from the fender liner to the fender. Tighten the screws to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 7430 4. Install the screws to the front fender liner to the front bumper fascia. Tighten the screws to 2 N.m (18 lb in). 5. Install the tire and wheel assembly. 6. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Description and Operation Body / Frame Mount Bushing: Description and Operation Floor Pan Insulators Description Floor pan insulators have been designed for the higher floor pan temperatures. Higher temperatures result from the use of the catalytic converter in the exhaust system. If you remove or disturb any insulators when servicing the vehicle in the field, reinstall the insulators in the original sequence and location. Use the material specified for that particular location on the floor pan if you replace an insulator. Important: Ensure that the following materials meet the Motor Vehicle Safety Standard Number 302 for flammability. * Floor pan insulator (cerra blanket thermal). Consists of 10 mm (3/8 in) thick aluminum silica (type 1). * Floor pan insulator (amberlite). Consists of 10 mm (3/8 in) thick resinated fibers (type 2). * Floor pan insulator sheet (phenolic bonded fiberglass) 305 x 457 mm (12 x 18 in) cut to size (type 3). Types 1 and 2 have the following characteristics: * Rolled stock * Ordered by linear foot * Cut to fit When servicing or replacing interior insulators, observe the following instructions: * Install the insulators in the original position and sequence. Place the pieces close together in order to avoid gapping or overlapping. * Use the original part for the following reasons: * In order to determine the amount of replacement material required * As a template for cutting and fitting the new piece to the floor pan * When installing the insulator, do not enlarge the cutouts or holes. The cutouts or holes are used for the attachment of the interior components such as seats or seat belts. * Route the cross body harnesses for the following interior components over the floor pan insulators and into the original location: * The power seats * The lap belt warning light and alarm * The rear speakers Clip the cross body harnesses into place. * Do not apply the spray-on deadeners and trim adhesive to the top of the floor pan at the area located directly over the catalytic converter or muffler(s). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement Cross-Member: Service and Repair Cross Vehicle Brace Replacement Cross Vehicle Brace Replacement Removal Procedure 1. Remove the right front fender liner. 2. Remove the wiring harness retainers. 3. Remove the front suspension support brace. 4. Remove the lower brace bolts (2). 5. Remove the lower brace (1) from the vehicle. Installation Procedure 1. Install the lower brace (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower brace bolts (2). Tighten the lower brace bolts to 25 N.m (18 lb ft). 3. Install the front suspension support brace. 4. Install the wiring harness retainers. 5. Install the right front fender liner. Front Fender Liner Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement > Page 7439 Cross-Member: Service and Repair Frame and Underbody Crossmember Replacement Removal Procedure 1. Raise and support the vehicle.Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the front fender liners. 4. Remove the engine strut from the lower engine mount and frame. 5. Remove the front exhaust pipe. 6. Disconnect the ABS harness from the lower control arms. 7. Disconnect the ball joints from the steering knuckles. 8. Disconnect the tie rods from the steering knuckles. 9. On vehicles with a brake pipe running along the crossmember, disconnect the brake pipe from the retainers. 10. Remove the power steering gear to crossmember mounting bolts. 11. Secure the power steering gear to the body, taking care not to over extend the intermediate shaft. 12. Remove the front suspension support brace. 13. Support the crossmember, using suitable jack stands. 14. Remove the front suspension crossmember mounting bolts. 15. Lower the crossmember from the vehicle. 16. If replacing the crossmember, remove the following components: * The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement. Installation Procedure 1. If replacing the crossmember, Install the following components: * The stabilizer shaft. Refer to Stabilizer Shaft Replacement. * The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. 2. Using suitable jack stands, raise the crossmember to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Cross Vehicle Brace Replacement > Page 7440 3. Install the front suspension crossmember mounting bolts. 1. Tighten the left rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees. 2. Tighten the right rear outboard bolt to 110 N.m (81 lb ft) plus an additional 90 degrees. 3. Tighten the front upper bolts to 110 N.m (81 lb ft) plus an additional 90 degrees. 4. Tighten the rear inboard bolts to 110 N.m (81 lb ft) plus an additional 90 degrees. 4. Install the front suspension support brace. 5. Reposition the steering gear to the crossmember. 6. Install the power steering gear to crossmember mounting bolts. Tighten the bolts to 120 N.m (89 lb ft). 7. On vehicles with the brake pipe running along the support frame, install the brake pipe into the retainers. 8. Connect the tie rods to the steering knuckle. 9. Connect the lower control arms to the steering knuckles. 10. Connect the ABS harness to the lower control arms. 11. Install the front exhaust pipe. 12. Install the engine strut to the lower engine mount and frame. 13. Install the front fender liners. 14. Install the tire and wheel assemblies. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > System Diagnosis Front Subframe: Testing and Inspection Checking Frame Alignment The main components of the frame are the side rails and the crossmembers. The rails carry the load. The crossmembers stabilize the rails. The 5 types of frame misalignment are the following: * Sag * Buckle * Diamond * Sidesway * Twist A misaligned frame rail may move in the following directions from where the frame rail should be: * Forward * Up * Down * To the side The easiest way to inspect the frame alignment is with gauges that are made for this purpose. Detailed instructions are normally supplied with the gauges at the time of purchase. There are no instructions for gauge use in the manual. Whether you inspect the alignment with or without gauges, park the vehicle on a level section of floor. Certain conditions call for preliminary inspections before inspecting the frame. Suspension or axle problems may make it appear that the vehicle frame is out of alignment. If an axle has shifted, diamond or sidesway may appear to exist when neither do exist. A weak spring may make the vehicle appear to have a twisted frame. A visual inspection of the top and the bottom flanges of each rail may reveal the specific area where the sag or the buckle exist. In the case of a sag, wrinkles may appear on the top of the upper flange. The wrinkles are definite evidence of sag. Wrinkles on the bottom of the lower flange are definite evidence of buckle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement Arm Rest: Service and Repair Armrest Bracket Replacement Armrest Bracket Replacement Removal Procedure 1. Remove the door trim panel. 2. Drill out the rivets (3) which retain the door armrest hanger plate (1). 3. Remove the door armrest hanger plate (1) from the door. Installation Procedure 1. Position the door armrest hanger plate (1) to the door. 2. Install the new rivets (3) to the door hanger plate. 3. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Bracket Replacement > Page 7450 Arm Rest: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. Installation Procedure 1. Install the front floor console armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front floor console armrest hinge. Tighten the screws to 2.3 N.m (20 lb in). 3. Lower the front floor console armrest. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7455 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7456 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7457 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7458 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7459 Carpet: Technical Service Bulletins Interior - Carpet Wet On Driver's Side Carpet Wet on Drivers Side (Seal Sheet Metal Seam) #03-08-63-002 - (Jul 22, 2003) Carpet Wet On Driver's Side (Seal Sheet Metal Seam) 2000-2004 Chevrolet Cavalier 2000-2004 Pontiac Sunfire Condition Some customers may comment that the carpeting is wet on the driver's side. Cause This condition may be due to lack of body sealer at the bulk head just above the throttle cable. Refer to the illustration above. Correction Reseal the bulk head. 1. Clean the area with denatured alcohol. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 7460 2. Apply a bead of *Kent High Tech Clear Seam Sealer, P/N 10200, to the area. Refer to the illustration above. 3. Let the sealer dry and check for leaks. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. * Instructions and cautions are printed on the bottle, but additional help is available. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 7463 Carpet: Removal and Replacement Front Floor Panel Carpet Replacement Front Floor Panel Carpet Replacement Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system, if equipped with Side Impact Air Bags (SIAB). Refer to SIR Disabling and Enabling and to SIR Disabling and Enabling in Restraint Systems. 2. Remove the front seats. 3. Remove the rear seat cushion. 4. Remove the front seat belt anchor bolts form the floor pan. 5. Remove the seat belt anchor plate from the floor pan. 6. Remove the floor console. 7. On the coupe, remove the rear quarter trim panel. 8. On the sedan, remove the lower rear quarter trim panel. 9. Remove the floor carpet retainers. 10. Remove the floor carpet. Installation 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. Install the floor carpet. 2. Install the floor carpet retainers. 3. On the sedan install the lower rear quarter trim panel. 4. On the coupe install the rear quarter trim panel. 5. Install the floor console. 6. Install the seat belt anchor plate to the floor pan. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 7464 7. Install the front seat belt anchor bolts. Tighten the bolts to 41 N.m (30 lb ft). 8. Install the rear seat cushion. 9. Install the front seats. 10. Enable the SIR system, if equipped with SIAB. Refer to SIR Disabling and Enabling and to SIR Disabling and Enabling in Restraint Systems. Carpet Retainer Replacement (Coupe) Carpet Retainer Replacement (Coupe) Removal Procedure 1. Disengage the tab at the hood latch release handle. 2. Starting at the rear, pull the carpet retainer upward to disengage the fasteners. 3. Remove the retainer (1) from the vehicle. Installation Procedure 1. Position the retainer (1) into the vehicle. 2. Press down on the retainer (1) until fasteners are fully engaged. 3. Align the tab at the hood latch release handle. Press until fully engaged. Carpet Retainer Replacement (Sedan) Carpet Retainer Replacement (Sedan) Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system, if equipped with Side Impact Air Bags (SIAB). Refer to SIR Disabling and Enabling and SIR Disabling and Enabling in Restraints. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 7465 2. Remove the rear quarter lower trim panel. 3. Remove the center pillar upper trim panel. 4. Pull up on the carpet retainer (1) to disengage the fasteners. 5. Remove the carpet retainer (1) from the vehicle. Installation Procedure 1. Position the carpet retainer (1) in the vehicle. 2. Press down on the carpet retainer (1) until fasteners are fully engaged. 3. Install the center pillar upper trim panel. 4. Install the rear quarter trim lower panel. 5. Enable the SIR system, if equipped with Side Impact Air Bags (SIAB). Refer to SIR Disabling and Enabling, and SIR Disabling and Enabling in Restraints. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications Console: Specifications Fastener Tightening Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7469 Console: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE Key And Lock Cylinder Coding The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with five different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the IP storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS The key code can be obtained from the five-digit number on the key tag that accompanies the original master and valet keys. The five-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and five key cut depths (2). Key cut positions are numbered Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7470 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to appropriate service procedure for programing the keys to the vehicle. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments: With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. LOCK CYLINDER TUMBLER OPERATION Each of the four cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The IP storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the IP storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses only seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side, four on one side and three on the other. Assembling And Coding Ignition Lock Cylinder 1. Hold the cylinder (7) so that the side with four tumbler spring wells is facing up. 2. Insert tumbler springs (5) into the four spring wells. 3. The first tumbler to be loaded will be the 3rd key cut position the 3rd number in the key code. Install the first tumbler (4) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the three remaining tumblers on this side of the lock cylinder, key cut positions 5, 7 and 9. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. 8. Insert the tumbler springs (5) into the three spring wells. 9. Install the tumbler (4) for the key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7471 13. Lightly lubricate the tumbler (4) surfaces using the provided lubrication. 14. With the key inserted into the housing, align the retaining bar with the groove on the inside diameter of the cylinder housing. This groove extends through to the back of the lock housing (6). 15. Lifting the flat spring and button, install the cylinder (7) into the cylinder housing (6). The retainer bar snaps into place when the cylinder (7) is fully seated. ASSEMBLING AND CODING DOOR LOCK CYLINDER The door lock cylinder only uses seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. Assembling And Coding Door Lock Cylinder 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The door lock cylinder tumblers are not self-retaining. Hold the tumblers in place when the key is not in the lock cylinder. Hold the lock tumblers (12) in place when performing the next steps. 2. Insert tumbler springs (11) into the four spring wells. 3. Install the tumbler for key cut position 3 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (11) into the 3 spring wells. 9. Install the tumbler for key cut position 4 into the slot nearest the front of the lock cylinder. 10. Install the 2 remaining tumblers for key cut positions 6 and 8 on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (12) surfaces using the provided lubrication. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7472 14. Install the 2 plate springs (6) into the 2 spring wells in the head of the door lock cylinder (5). 15. Snap the shutter assembly (8) onto the cylinder. 16. Insert the key into the lock cylinder. 17. Place the detent spring (10) into the spring well located on the side of the lock cylinder (5). 18. Carefully place the detent ball (9) on the detent spring (10). 19. Depress the detent ball and spring and insert the cylinder (5) into the cylinder housing (4). CAUTION: Wear safety glasses in order to avoid eye damage. 20. Install the lock pawl (3). 21. Install the lock pawl E-clip (2) to retain the lock pawl. 22. Remove the key from the lock cylinder (5). 23. Install the lock cylinder cap (7) by aligning the notch in the cap with the large drain slot in the lock housing (4). Press the cap into place with light hand pressure. ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 3-9. The tumbler positions are staggered from side to side (4 on one side and 3 on the other). Assembling And Coding Rear Compartment Lid Lock 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Insert the tumbler (6) for key cut position 3 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (6) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (4) into the 3 spring wells. 9. Install the tumbler (6) for key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7473 11. Snap the tumblers into place with light hand pressure. 12. Inspect for the correct loading of the tumblers (6) by inserting the key into the cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (6) surfaces using the provided lubrication. 14. Install the lock cylinder (5) into lock cylinder housing (12). IMPORTANT: The key must be in the lock cylinder (5) when performing this step. 15. Rotate the lock cylinder (5) counterclockwise until it stops. 16. Remove the key from the lock cylinder (5). 17. Insert two plate springs (3) into the spring wells in the head of the lock cylinder (5). 18. Line up the shutter pins with the pin pockets and snap shutter (2) onto the lock cylinder (5), by pressing on the face of the shutter with light hand pressure. 19. Note the position of the two dimples on the side of the lock cylinder housing. 20. Align the cut-out on dust cover (1) with widest lug on the lock cylinder housing (12). 21. Install the dust cover (1) over head of the lock cylinder housing (12). 22. Using a small punch or drift, stake the dust cover (1) onto the lock cylinder housing (12) at the 2 dimples on the side of the lock cylinder. 23. Align the widest slot on the lock cylinder housing (12) with the widest rib in the inside diameter of the base (7). 24. Install the cylinder and housing (12) into the back of the base assembly (7). Use thumb pressure, as necessary. 25. Install the compression spring (13) into the back of the base assembly (7) 26. Assemble the torsion spring (11) onto the lock cylinder shaft (9). 27. Slide the torsion spring (11) toward the large end of the shaft (9) with the interior leg of the spring facing the larger end of the shaft. 28. Align the ribs on the inner surface of the switch (10) bore with the grooves on the shaft (9). 29. Install the shaft (9) through the switch (10) to the following position: - The wires on the switch (10) face the large end of the shaft (9). - The large groove on the shaft (9) is 180 degrees from the switch wires (10). 30. Install switch and shaft (1 and 3) into the rear of the retainer (14). 31. Looking at the large end of shaft (9), rotate shaft counterclockwise until it stops. 32. Align the retainer (14) to the base (7). Align the wide slot on the retainer to the widest rib on the inner surface of the base. 33. Push the retainer (14) inward, while turning the key in order to align the shaft (9). 34. Push in the retainer (14) to compress spring (13). Turn the retainer (14) approximately 1/8 turn counterclockwise. 35. Engage the torsion spring (11) onto the lug on the retainer (14). 36. Install the retainer clip (8) onto the base (7). 37. Install the gasket onto the base (7). 38. Inspect the operation of the lock assembly. The torsion spring (11) should provide a counterclockwise snap back. ASSEMBLING AND CODING IP STORAGE COMPARTMENT LOCK CYLINDER The IP storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the IP storage compartment lock to retain the lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the IP storage compartment lock cylinder and should come already installed in the cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications > Page 7474 Assembling And Coding IP Storage Compartment Lock Cylinder 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor Console: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. Installation Procedure 1. Install the front floor console armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front floor console armrest hinge. Tighten the screws to 2.3 N.m (20 lb in). 3. Lower the front floor console armrest. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7477 Console: Service and Repair Console Shift Boot Replacement Console Shift Boot Replacement Removal Procedure 1. Remove the front floor console. 2. Release the front tab retainer using a small flat-bladed tool and pushing back and down on the shifter boot retainer tab. 3. Remove the console shift boot from the front floor console by releasing the remainder of the retainers and pulling from the front floor console. Installation Procedure 1. Position the shifter boot front retainer tab to the front floor console. 2. Install the shifter boot by pressing into place until fully seated. 3. Install the front floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7478 Console: Service and Repair Console Trim Plate Replacement Console Trim Plate Replacement Removal Procedure 1. Remove the front floor console. 2. With a flat-bladed tool, release the retaining lip from the trim plate bezel. 3. Pull the bezel up and out of the floor console. Installation Procedure 1. Align the trim plate bezel to the front floor console. 2. Press the bezel into the floor console until the bezel is fully seated. 3. Install the front floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7479 Console: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. Installation Procedure 1. Install the front floor console armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front floor console armrest hinge. Tighten the screws to 2.3 N.m (20 lb in). 3. Lower the front floor console armrest. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7480 Console: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. Installation Procedure 1. Install the front floor console armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front floor console armrest hinge. Tighten the screws to 2.3 N.m (20 lb in). 3. Lower the front floor console armrest. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7481 Console Shift Boot Replacement Console Shift Boot Replacement Removal Procedure 1. Remove the front floor console. 2. Release the front tab retainer using a small flat-bladed tool and pushing back and down on the shifter boot retainer tab. 3. Remove the console shift boot from the front floor console by releasing the remainder of the retainers and pulling from the front floor console. Installation Procedure 1. Position the shifter boot front retainer tab to the front floor console. 2. Install the shifter boot by pressing into place until fully seated. 3. Install the front floor console. Console Trim Plate Replacement Console Trim Plate Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7482 1. Remove the front floor console. 2. With a flat-bladed tool, release the retaining lip from the trim plate bezel. 3. Pull the bezel up and out of the floor console. Installation Procedure 1. Align the trim plate bezel to the front floor console. 2. Press the bezel into the floor console until the bezel is fully seated. 3. Install the front floor console. Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the front floor console armrest hinge at the front floor console armrest. 3. Remove the front floor console armrest from the front floor console. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7483 1. Install the front floor console armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front floor console armrest hinge. Tighten the screws to 2.3 N.m (20 lb in). 3. Lower the front floor console armrest. Front Floor Console Replacement Front Floor Console Replacement Removal Procedure 1. On vehicles with manual transmission, release the snaps on the shift boot. 2. Using a small flat-bladed tool, remove the front bolt cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7484 3. Using a small flat-bladed tool, remove the center storage pocket, if equipped. 4. Remove the power window switch plate, if equipped. 5. Raise the armrest (1) from the front floor console. 6. Remove the bolts (6) from the front floor console. 7. Remove the front floor console by lifting up and back. Guide the shift boot over the optional shift knob and over the park brake handle. Installation Procedure 1. Install the front floor console by guiding the shift boot over the optional shift knob and over the park brake handle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7485 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (6) to the front floor console. Tighten the bolts to 6 N.m (53 lb in). 3. Lower the armrest (1). 4. Install the optional center storage pocket. Press into place until fully seated. 5. Install the optional power window switch plate. 6. Install the front bolt cover. Press into place until fully seated. 7. On vehicles with manual transmission, attach the snaps on the shift boot. Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7486 Key And Lock Cylinder Coding The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with five different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the IP storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS The key code can be obtained from the five-digit number on the key tag that accompanies the original master and valet keys. The five-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and five key cut depths (2). Key cut positions are numbered 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to appropriate service procedure for programing the keys to the vehicle. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments: With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7487 - Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. LOCK CYLINDER TUMBLER OPERATION Each of the four cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The IP storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the IP storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses only seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side, four on one side and three on the other. Assembling And Coding Ignition Lock Cylinder 1. Hold the cylinder (7) so that the side with four tumbler spring wells is facing up. 2. Insert tumbler springs (5) into the four spring wells. 3. The first tumbler to be loaded will be the 3rd key cut position the 3rd number in the key code. Install the first tumbler (4) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the three remaining tumblers on this side of the lock cylinder, key cut positions 5, 7 and 9. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. 8. Insert the tumbler springs (5) into the three spring wells. 9. Install the tumbler (4) for the key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (4) surfaces using the provided lubrication. 14. With the key inserted into the housing, align the retaining bar with the groove on the inside diameter of the cylinder housing. This groove extends through to the back of the lock housing (6). 15. Lifting the flat spring and button, install the cylinder (7) into the cylinder housing (6). The retainer bar snaps into place when the cylinder (7) is fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7488 ASSEMBLING AND CODING DOOR LOCK CYLINDER The door lock cylinder only uses seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. Assembling And Coding Door Lock Cylinder 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The door lock cylinder tumblers are not self-retaining. Hold the tumblers in place when the key is not in the lock cylinder. Hold the lock tumblers (12) in place when performing the next steps. 2. Insert tumbler springs (11) into the four spring wells. 3. Install the tumbler for key cut position 3 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (11) into the 3 spring wells. 9. Install the tumbler for key cut position 4 into the slot nearest the front of the lock cylinder. 10. Install the 2 remaining tumblers for key cut positions 6 and 8 on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (12) surfaces using the provided lubrication. 14. Install the 2 plate springs (6) into the 2 spring wells in the head of the door lock cylinder (5). 15. Snap the shutter assembly (8) onto the cylinder. 16. Insert the key into the lock cylinder. 17. Place the detent spring (10) into the spring well located on the side of the lock cylinder (5). 18. Carefully place the detent ball (9) on the detent spring (10). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7489 19. Depress the detent ball and spring and insert the cylinder (5) into the cylinder housing (4). CAUTION: Wear safety glasses in order to avoid eye damage. 20. Install the lock pawl (3). 21. Install the lock pawl E-clip (2) to retain the lock pawl. 22. Remove the key from the lock cylinder (5). 23. Install the lock cylinder cap (7) by aligning the notch in the cap with the large drain slot in the lock housing (4). Press the cap into place with light hand pressure. ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 3-9. The tumbler positions are staggered from side to side (4 on one side and 3 on the other). Assembling And Coding Rear Compartment Lid Lock 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Insert the tumbler (6) for key cut position 3 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (6) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (4) into the 3 spring wells. 9. Install the tumbler (6) for key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for the correct loading of the tumblers (6) by inserting the key into the cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (6) surfaces using the provided lubrication. 14. Install the lock cylinder (5) into lock cylinder housing (12). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7490 IMPORTANT: The key must be in the lock cylinder (5) when performing this step. 15. Rotate the lock cylinder (5) counterclockwise until it stops. 16. Remove the key from the lock cylinder (5). 17. Insert two plate springs (3) into the spring wells in the head of the lock cylinder (5). 18. Line up the shutter pins with the pin pockets and snap shutter (2) onto the lock cylinder (5), by pressing on the face of the shutter with light hand pressure. 19. Note the position of the two dimples on the side of the lock cylinder housing. 20. Align the cut-out on dust cover (1) with widest lug on the lock cylinder housing (12). 21. Install the dust cover (1) over head of the lock cylinder housing (12). 22. Using a small punch or drift, stake the dust cover (1) onto the lock cylinder housing (12) at the 2 dimples on the side of the lock cylinder. 23. Align the widest slot on the lock cylinder housing (12) with the widest rib in the inside diameter of the base (7). 24. Install the cylinder and housing (12) into the back of the base assembly (7). Use thumb pressure, as necessary. 25. Install the compression spring (13) into the back of the base assembly (7) 26. Assemble the torsion spring (11) onto the lock cylinder shaft (9). 27. Slide the torsion spring (11) toward the large end of the shaft (9) with the interior leg of the spring facing the larger end of the shaft. 28. Align the ribs on the inner surface of the switch (10) bore with the grooves on the shaft (9). 29. Install the shaft (9) through the switch (10) to the following position: - The wires on the switch (10) face the large end of the shaft (9). - The large groove on the shaft (9) is 180 degrees from the switch wires (10). 30. Install switch and shaft (1 and 3) into the rear of the retainer (14). 31. Looking at the large end of shaft (9), rotate shaft counterclockwise until it stops. 32. Align the retainer (14) to the base (7). Align the wide slot on the retainer to the widest rib on the inner surface of the base. 33. Push the retainer (14) inward, while turning the key in order to align the shaft (9). 34. Push in the retainer (14) to compress spring (13). Turn the retainer (14) approximately 1/8 turn counterclockwise. 35. Engage the torsion spring (11) onto the lug on the retainer (14). 36. Install the retainer clip (8) onto the base (7). 37. Install the gasket onto the base (7). 38. Inspect the operation of the lock assembly. The torsion spring (11) should provide a counterclockwise snap back. ASSEMBLING AND CODING IP STORAGE COMPARTMENT LOCK CYLINDER The IP storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the IP storage compartment lock to retain the lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the IP storage compartment lock cylinder and should come already installed in the cylinder. Assembling And Coding IP Storage Compartment Lock Cylinder 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7491 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Power Accessory Receptacle Replacement - Floor Console ACCESSORY POWER RECEPTACLE REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigarette Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power accessory port fuse. 2. Remove the power accessory port access cover. 3. Remove the power accessory port housing by placing one side of the "T" portion of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory port housing straight out. 4. Remove J 42059 from the power accessory port housing. 5. Disconnect the electrical connector from the power accessory port housing. 6. Using your index finger pull out the power accessory port retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 7492 7. If the standard method fails to remove the socket, use the following alternate method: 7.1. Insert a small grinding tool (2) with a cutoff wheel into the socket. 7.2. Remove the plastic latches (1) in the 3-mm (0.11-in) square windows. 7.3. Use J 42059 as directed above to remove the socket. IMPORTANT: If tool fails to remove power accessory port. INSTALLATION PROCEDURE 1. Install the power accessory port retainer by pressing the retainer into place until fully seated. 2. Connect the electrical connector to the power accessory port housing. 3. Align the power accessory port housing to the slots in the retainer opening. 4. Install the power accessory port housing to the retainer opening. 5. Press the power accessory port into place until fully seated in the retainer. 6. Install the power accessory port fuse. 7. Inspect the power accessory port for proper operation. 8. Install the power accessory port housing access cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 7493 Console: Tools and Equipment Special Tools Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7499 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7500 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7501 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7502 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7503 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7504 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7505 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7506 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7507 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7508 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7509 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7510 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7511 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7512 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7513 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7514 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7515 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7516 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7517 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7518 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7519 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7520 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7521 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7522 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7523 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7524 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair > Latch Replacement - IP Compartment Glove Compartment Lock: Service and Repair Latch Replacement - IP Compartment LATCH REPLACEMENT - INSTRUMENT PANEL (I/P) COMPARTMENT REMOVAL PROCEDURE 1. Open the instrument panel (I/P) compartment door. 2. Remove the reinforcement cover from the I/P door. 3. Disconnect the anti-rattle device from the door latch mounting point, if equipped. 4. Remove the screws (1) from the I/P compartment door latch (2). 5. Remove the door latch (2) from the I/P compartment door (3). 6. Remove the anti-rattle device from the door latch (2), if equipped. 7. Remove the door latch handle from the I/P compartment door. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair > Latch Replacement - IP Compartment > Page 7530 1. Install the door latch handle to the I/P compartment door. 2. Install the anti-rattle device to the door latch (2), if equipped. 3. Install the door latch (2) to the I/P compartment door (3). 4. Install the I/P compartment door latch screws (1). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.3 N.m (20 lb in). 5. Connect the anti-rattle device to the door latch mounting point, if equipped. 6. Install the inner I/P reinforcement cover to the I/P compartment door. 7. Inspect the I/P compartment door for proper operation. 8. Close the I/P compartment door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Service and Repair > Latch Replacement - IP Compartment > Page 7531 Glove Compartment Lock: Service and Repair Striker Replacement - Instrument Panel (I/P) Compartment STRIKER REPLACEMENT - INSTRUMENT PANEL (I/P) COMPARTMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) trim pad. 2. Open the compartment door. 3. Remove the screws (2) holding the compartment striker (3) to the I/P carrier (1). 4. Remove the striker (3) from the I/P carrier (1). INSTALLATION PROCEDURE 1. Install the striker (3) to the I/P carrier (1). 2. Install the screws (2) to the striker (3). 3. Adjust the striker (3) for proper alignment to the I/P compartment. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2.3 N.m (20 lb in). 4. Install the I/P trim pad. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation Glove Compartment Lock Cylinder: Description and Operation KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE Key And Lock Cylinder Coding The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with five different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the IP storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS The key code can be obtained from the five-digit number on the key tag that accompanies the original master and valet keys. The five-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and five key cut depths (2). Key cut positions are numbered Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 7535 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to appropriate service procedure for programing the keys to the vehicle. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments: With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. LOCK CYLINDER TUMBLER OPERATION Each of the four cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The IP storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the IP storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses only seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side, four on one side and three on the other. Assembling And Coding Ignition Lock Cylinder 1. Hold the cylinder (7) so that the side with four tumbler spring wells is facing up. 2. Insert tumbler springs (5) into the four spring wells. 3. The first tumbler to be loaded will be the 3rd key cut position the 3rd number in the key code. Install the first tumbler (4) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the three remaining tumblers on this side of the lock cylinder, key cut positions 5, 7 and 9. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. 8. Insert the tumbler springs (5) into the three spring wells. 9. Install the tumbler (4) for the key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 7536 13. Lightly lubricate the tumbler (4) surfaces using the provided lubrication. 14. With the key inserted into the housing, align the retaining bar with the groove on the inside diameter of the cylinder housing. This groove extends through to the back of the lock housing (6). 15. Lifting the flat spring and button, install the cylinder (7) into the cylinder housing (6). The retainer bar snaps into place when the cylinder (7) is fully seated. ASSEMBLING AND CODING DOOR LOCK CYLINDER The door lock cylinder only uses seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. Assembling And Coding Door Lock Cylinder 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The door lock cylinder tumblers are not self-retaining. Hold the tumblers in place when the key is not in the lock cylinder. Hold the lock tumblers (12) in place when performing the next steps. 2. Insert tumbler springs (11) into the four spring wells. 3. Install the tumbler for key cut position 3 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (11) into the 3 spring wells. 9. Install the tumbler for key cut position 4 into the slot nearest the front of the lock cylinder. 10. Install the 2 remaining tumblers for key cut positions 6 and 8 on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (12) surfaces using the provided lubrication. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 7537 14. Install the 2 plate springs (6) into the 2 spring wells in the head of the door lock cylinder (5). 15. Snap the shutter assembly (8) onto the cylinder. 16. Insert the key into the lock cylinder. 17. Place the detent spring (10) into the spring well located on the side of the lock cylinder (5). 18. Carefully place the detent ball (9) on the detent spring (10). 19. Depress the detent ball and spring and insert the cylinder (5) into the cylinder housing (4). CAUTION: Wear safety glasses in order to avoid eye damage. 20. Install the lock pawl (3). 21. Install the lock pawl E-clip (2) to retain the lock pawl. 22. Remove the key from the lock cylinder (5). 23. Install the lock cylinder cap (7) by aligning the notch in the cap with the large drain slot in the lock housing (4). Press the cap into place with light hand pressure. ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 3-9. The tumbler positions are staggered from side to side (4 on one side and 3 on the other). Assembling And Coding Rear Compartment Lid Lock 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Insert the tumbler (6) for key cut position 3 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (6) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (4) into the 3 spring wells. 9. Install the tumbler (6) for key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 7538 11. Snap the tumblers into place with light hand pressure. 12. Inspect for the correct loading of the tumblers (6) by inserting the key into the cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (6) surfaces using the provided lubrication. 14. Install the lock cylinder (5) into lock cylinder housing (12). IMPORTANT: The key must be in the lock cylinder (5) when performing this step. 15. Rotate the lock cylinder (5) counterclockwise until it stops. 16. Remove the key from the lock cylinder (5). 17. Insert two plate springs (3) into the spring wells in the head of the lock cylinder (5). 18. Line up the shutter pins with the pin pockets and snap shutter (2) onto the lock cylinder (5), by pressing on the face of the shutter with light hand pressure. 19. Note the position of the two dimples on the side of the lock cylinder housing. 20. Align the cut-out on dust cover (1) with widest lug on the lock cylinder housing (12). 21. Install the dust cover (1) over head of the lock cylinder housing (12). 22. Using a small punch or drift, stake the dust cover (1) onto the lock cylinder housing (12) at the 2 dimples on the side of the lock cylinder. 23. Align the widest slot on the lock cylinder housing (12) with the widest rib in the inside diameter of the base (7). 24. Install the cylinder and housing (12) into the back of the base assembly (7). Use thumb pressure, as necessary. 25. Install the compression spring (13) into the back of the base assembly (7) 26. Assemble the torsion spring (11) onto the lock cylinder shaft (9). 27. Slide the torsion spring (11) toward the large end of the shaft (9) with the interior leg of the spring facing the larger end of the shaft. 28. Align the ribs on the inner surface of the switch (10) bore with the grooves on the shaft (9). 29. Install the shaft (9) through the switch (10) to the following position: - The wires on the switch (10) face the large end of the shaft (9). - The large groove on the shaft (9) is 180 degrees from the switch wires (10). 30. Install switch and shaft (1 and 3) into the rear of the retainer (14). 31. Looking at the large end of shaft (9), rotate shaft counterclockwise until it stops. 32. Align the retainer (14) to the base (7). Align the wide slot on the retainer to the widest rib on the inner surface of the base. 33. Push the retainer (14) inward, while turning the key in order to align the shaft (9). 34. Push in the retainer (14) to compress spring (13). Turn the retainer (14) approximately 1/8 turn counterclockwise. 35. Engage the torsion spring (11) onto the lug on the retainer (14). 36. Install the retainer clip (8) onto the base (7). 37. Install the gasket onto the base (7). 38. Inspect the operation of the lock assembly. The torsion spring (11) should provide a counterclockwise snap back. ASSEMBLING AND CODING IP STORAGE COMPARTMENT LOCK CYLINDER The IP storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the IP storage compartment lock to retain the lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the IP storage compartment lock cylinder and should come already installed in the cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Description and Operation > Page 7539 Assembling And Coding IP Storage Compartment Lock Cylinder 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures Glove Compartment Lock Cylinder: Procedures Key and Lock Cylinder Coding KEY AND LOCK CYLINDER CODING KEY IDENTIFICATION AND USAGE Key And Lock Cylinder Coding The keys are double sided and reversible. The master key and valet key contain transponders that are read by the theft deterrent system when the keys are used in the ignition. The keys have 10 cut positions (1) with five different depths (2). The keys that are furnished with the vehicle are: The master key, which contains a transponder (3). This key will operate all of the locks on the vehicle. - The valet key, which contains a transponder (3). This key will operate the front door locks and the ignition lock only. - The emergency key, which does not contain a transponder. This key will operate the door locks, rear compartment lock and the IP storage compartment lock only. This key is intended for emergency use only. CUTTING KEYS Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7542 The key code can be obtained from the five-digit number on the key tag that accompanies the original master and valet keys. The five-digit key code cross references to the cut and tumbler sequence. The keys have 10 key cut positions (1) and five key cut depths (2). Key cut positions are numbered 1-10, counting from the head of the key to the tip. The key cut depths are 1-5, cut depth number 1 is the deepest cut. The key transponder (3) in the master and valet key must be programmed to the vehicle. Refer to appropriate service procedure for programing the keys to the vehicle. 1. Cut a blank key to the proper depth and sequence of each of the tumbler positions. 2. Inspect the mechanical operation of the key in the lock cylinders in the doors, the ignition switch, the rear compartment lid and any storage compartments: With each side of the key pointing up inside the lock, inspect the operation of the lock in both directions. Turn the key both directions in each lock cylinder. - Turn the key with each side of the key pointing upward in each lock cylinder. 3. If replacing a master or valet key, program the key transponder to the vehicle. LOCK CYLINDER TUMBLER OPERATION Each of the four cut depths on the key has corresponding tumblers sometimes referred to as plates or wafers. The tumbler depth number is stamped on the tumblers for identification. The IP storage compartment lock cylinder also require a retainer tumbler. The retainer tumbler is not moved by the key, its function is to retain the IP storage compartment lock cylinder in the lock assembly. ASSEMBLING AND CODING IGNITION LOCK CYLINDER The ignition lock cylinder uses only seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side, four on one side and three on the other. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7543 Assembling And Coding Ignition Lock Cylinder 1. Hold the cylinder (7) so that the side with four tumbler spring wells is facing up. 2. Insert tumbler springs (5) into the four spring wells. 3. The first tumbler to be loaded will be the 3rd key cut position the 3rd number in the key code. Install the first tumbler (4) in the slot nearest the front of the lock cylinder, this is the side into which the key would be inserted. 4. Install the three remaining tumblers on this side of the lock cylinder, key cut positions 5, 7 and 9. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (7) so that the side with the 3 tumbler spring wells is facing up. 8. Insert the tumbler springs (5) into the three spring wells. 9. Install the tumbler (4) for the key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for correct loading of the tumblers (4) by inserting the key into cylinder (7). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (4) surfaces using the provided lubrication. 14. With the key inserted into the housing, align the retaining bar with the groove on the inside diameter of the cylinder housing. This groove extends through to the back of the lock housing (6). 15. Lifting the flat spring and button, install the cylinder (7) into the cylinder housing (6). The retainer bar snaps into place when the cylinder (7) is fully seated. ASSEMBLING AND CODING DOOR LOCK CYLINDER The door lock cylinder only uses seven of the ten cut positions, 3 through 9. The tumbler positions are staggered from side to side 4 on one side and 3 on the other. The left and right door lock cylinders are identical. The lock pawl determines which side of the vehicle the lock cylinder is on. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7544 Assembling And Coding Door Lock Cylinder 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. IMPORTANT: The door lock cylinder tumblers are not self-retaining. Hold the tumblers in place when the key is not in the lock cylinder. Hold the lock tumblers (12) in place when performing the next steps. 2. Insert tumbler springs (11) into the four spring wells. 3. Install the tumbler for key cut position 3 in the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (11) into the 3 spring wells. 9. Install the tumbler for key cut position 4 into the slot nearest the front of the lock cylinder. 10. Install the 2 remaining tumblers for key cut positions 6 and 8 on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Check for correct loading of the tumblers (12) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (12) surfaces using the provided lubrication. 14. Install the 2 plate springs (6) into the 2 spring wells in the head of the door lock cylinder (5). 15. Snap the shutter assembly (8) onto the cylinder. 16. Insert the key into the lock cylinder. 17. Place the detent spring (10) into the spring well located on the side of the lock cylinder (5). 18. Carefully place the detent ball (9) on the detent spring (10). 19. Depress the detent ball and spring and insert the cylinder (5) into the cylinder housing (4). CAUTION: Wear safety glasses in order to avoid eye damage. 20. Install the lock pawl (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7545 21. Install the lock pawl E-clip (2) to retain the lock pawl. 22. Remove the key from the lock cylinder (5). 23. Install the lock cylinder cap (7) by aligning the notch in the cap with the large drain slot in the lock housing (4). Press the cap into place with light hand pressure. ASSEMBLING AND CODING REAR COMPARTMENT LID LOCK The rear compartment lock cylinder only uses 7 of the 10 cut positions, 3-9. The tumbler positions are staggered from side to side (4 on one side and 3 on the other). Assembling And Coding Rear Compartment Lid Lock 1. Hold the cylinder (5) so that the side with 4 tumbler spring wells faces up. 2. Insert the tumbler springs (4) into the 4 spring wells. 3. Insert the tumbler (6) for key cut position 3 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 5, 7 and 9, on this side of the lock cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Check for correct loading of the tumblers (6) by inserting the key into cylinder (5). All of the tumblers should be flush with the lock cylinder. 7. Turn the cylinder (5) so that the side with 3 tumbler spring wells faces up. 8. Insert the tumbler springs (4) into the 3 spring wells. 9. Install the tumbler (6) for key cut position 4 into the slot nearest to the front of the lock cylinder. 10. Install the 2 remaining tumblers, key cut positions 6 and 8, on this side of the lock cylinder. 11. Snap the tumblers into place with light hand pressure. 12. Inspect for the correct loading of the tumblers (6) by inserting the key into the cylinder (5). All of the tumblers should be flush with the lock cylinder. 13. Lightly lubricate the tumbler (6) surfaces using the provided lubrication. 14. Install the lock cylinder (5) into lock cylinder housing (12). IMPORTANT: The key must be in the lock cylinder (5) when performing this step. 15. Rotate the lock cylinder (5) counterclockwise until it stops. 16. Remove the key from the lock cylinder (5). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7546 17. Insert two plate springs (3) into the spring wells in the head of the lock cylinder (5). 18. Line up the shutter pins with the pin pockets and snap shutter (2) onto the lock cylinder (5), by pressing on the face of the shutter with light hand pressure. 19. Note the position of the two dimples on the side of the lock cylinder housing. 20. Align the cut-out on dust cover (1) with widest lug on the lock cylinder housing (12). 21. Install the dust cover (1) over head of the lock cylinder housing (12). 22. Using a small punch or drift, stake the dust cover (1) onto the lock cylinder housing (12) at the 2 dimples on the side of the lock cylinder. 23. Align the widest slot on the lock cylinder housing (12) with the widest rib in the inside diameter of the base (7). 24. Install the cylinder and housing (12) into the back of the base assembly (7). Use thumb pressure, as necessary. 25. Install the compression spring (13) into the back of the base assembly (7) 26. Assemble the torsion spring (11) onto the lock cylinder shaft (9). 27. Slide the torsion spring (11) toward the large end of the shaft (9) with the interior leg of the spring facing the larger end of the shaft. 28. Align the ribs on the inner surface of the switch (10) bore with the grooves on the shaft (9). 29. Install the shaft (9) through the switch (10) to the following position: - The wires on the switch (10) face the large end of the shaft (9). - The large groove on the shaft (9) is 180 degrees from the switch wires (10). 30. Install switch and shaft (1 and 3) into the rear of the retainer (14). 31. Looking at the large end of shaft (9), rotate shaft counterclockwise until it stops. 32. Align the retainer (14) to the base (7). Align the wide slot on the retainer to the widest rib on the inner surface of the base. 33. Push the retainer (14) inward, while turning the key in order to align the shaft (9). 34. Push in the retainer (14) to compress spring (13). Turn the retainer (14) approximately 1/8 turn counterclockwise. 35. Engage the torsion spring (11) onto the lug on the retainer (14). 36. Install the retainer clip (8) onto the base (7). 37. Install the gasket onto the base (7). 38. Inspect the operation of the lock assembly. The torsion spring (11) should provide a counterclockwise snap back. ASSEMBLING AND CODING IP STORAGE COMPARTMENT LOCK CYLINDER The IP storage compartment lock only uses 4 of the 10 cut positions 7-10. A retainer tumbler is used in the IP storage compartment lock to retain the lock cylinder in the latch assembly. This retainer tumbler is not moved by the key. The retainer tumbler occupies the slot closest to the head of the IP storage compartment lock cylinder and should come already installed in the cylinder. Assembling And Coding IP Storage Compartment Lock Cylinder 1. Hold the cylinder (3) so that the side with 4 tumbler spring wells is facing up. 2. Insert tumbler springs (2) into the 4 spring wells. 3. Install the tumbler (1) for key cut position 7 into the slot nearest to the front of the lock cylinder. 4. Install the 3 remaining tumblers, key cut positions 8, 9 and 10, into the cylinder. 5. Snap the tumblers into place with light hand pressure. 6. Inspect for the correct loading of the tumblers (1) by inserting the key into cylinder (3). All of the tumblers should be flush with the lock cylinder. Lock Cylinder Replacement - I/P Compartment Door LOCK CYLINDER REPLACEMENT - I/P COMPARTMENT DOOR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7547 REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) latch. 2. Depress the lock cylinder retaining tab (1) located on the bottom of the lock cylinder (2). 3. Press out the lock cylinder from the I/P compartment door. INSTALLATION PROCEDURE 1. Align the lock cylinder to the opening in the I/P compartment door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7548 2. Depress the retaining tab (1) while installing the lock cylinder (2) to the I/P compartment door (4). 3. Install the I/P latch to the I/P compartment door. 4. Test the I/P compartment door and lock cylinder for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7549 Glove Compartment Lock Cylinder: Removal and Replacement Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Remove the instrument panel (I/P) latch. 2. Depress the lock cylinder retaining tab (1) located on the bottom of the lock cylinder (2). 3. Press out the lock cylinder from the I/P compartment door. Installation Procedure 1. Align the lock cylinder to the opening in the I/P compartment door. 2. Depress the retaining tab (1) while installing the lock cylinder (2) to the I/P compartment door (4). 3. Install the I/P latch to the I/P compartment door. 4. Test the I/P compartment door and lock cylinder for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headlining Trim Panel Replacement Removal Procedure Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. 1. Remove the sunshades. 2. Remove the coat hooks. 3. Remove the windshield upper garnish moldings. 4. On the sedan perform the following procedures: 1. Remove the center pillar upper trim panel. 2. Remove the upper rear quarter trim panel. 5. On the coupe remove the rear quarter trim panel. 6. Remove the finish lace from the sunroof opening trim, if equipped. 7. Remove the sunroof power switch, if equipped. 8. Disconnect the electrical connector (2) for the dome lamp wire harness (1) located on the instrument panel (I/P) lower tie bar (4) by the body control module (BCM). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7553 9. Remove the rosebud clips retaining the dome lamp wire harness (6) from the windshield pillar. 10. Route the dome lamp wire harness (6) through the opening along the windshield pillar. On the Cavalier remove enough of the I/P carrier to route the dome lamp wire harness (6) through the opening along the windshield pillar. Refer to Instrument Panel Carrier Replacement (Chevrolet) Instrument Panel Carrier Replacement (Pontiac) in Instrument Panel, Gages, and Console. 11. Disconnect the electrical connector (4) for the rear view mirror, if required. 12. If equipped with OnStar(R) perform the following procedures: 1. Disconnect the coaxial cable connectors from the OnStar(R) module. 2. Remove the rosebud clips retaining the OnStar(R) coaxial cable harness (3) windshield pillar. 3. Route the OnStar(R) coaxial cable harness (3) through the opening along the windshield pillar. 4. Disconnect the coaxial cable connector (8) for the OnStar(R) cellular antenna. 13. If the vehicle is equipped with a digital radio, perform the following procedures: 1. Disconnect the coaxial cable connector from the digital radio receiver 2. Remove the rosebud clips retaining the coaxial cable harness (10) to the upper rear quarter panel and the rear shelf. 14. If the vehicle is equipped with a GPS sensor, perform the following procedure: 1. Disconnect the coaxial cable electrical connector for the GPS sensor. 2. Remove the rosebud clips retaining the GPS sensor coaxial cable harness (9) from the upper rear quarter panel. 15. Remove the push-in retainers (5) from the headliner (1). 16. Lower the headliner (1). 17. Disconnect the coaxial cable connectors (2) form the digital radio antenna, if equipped. 18. Remove the headliner (1) from the vehicle. 19. Remove the dome lamp assembly (7) from the headliner (1), if required. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7554 Notice: Use care when removing or installing the headliner. Excessive bending will damage the headliner. 1. Install the dome lamp assembly (7) to the headliner (1), if required. 2. Position the headliner (1) in the vehicle. 3. Connect the coaxial cable connectors (2) to the digital radio antenna, if equipped. 4. Position the headliner (1) to the vehicle roof. 5. Install the push-in retainers (5) to the headliner (1). 6. If the vehicle is equipped with a GPS sensor, perform the following procedure: 1. Connect the coaxial cable connector to the GPS sensor. 2. Install the rosebud clips retaining the GPS sensor coaxial cable harness (9) to the upper rear quarter panel. 7. If the vehicle is equipped with a digital radio, perform the following procedure: 1. Connect the coaxial cable connector to the digital radio receiver. 2. Install the rosebud clips retaining the coaxial cable harness (10) to the upper rear quarter panel and the rear shelf. 8. Connect the electrical connector (4) for the rear view mirror, if required. 9. If equipped with OnStar(R) perform the following procedure: 1. Connect the coaxial cable connector (8) for the OnStar(R) cellular antenna. 2. Route the OnStar(R) coaxial cable harness (3) through the opening along the windshield pillar. 3. Install the rosebud clips retaining the OnStar(R) coaxial cable harness (3) to the windshield pillar. 4. Connect the coaxial cable connectors to the OnStar(R) module. 10. Route the dome lamp wire harness (6) through the opening in the windshield pillar. On the Cavalier install the I/P carrier. 11. Install the rosebud clips retaining the dome lamp wire harness (6) to the windshield pillar. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 7555 12. Connect the electrical connector (2) for the dome lamp wire harness (1) located on the I/P lower tie bar (4) by the BCM. 13. Install the sunroof power switch, if equipped. 14. Install the finish lace to the sunroof opening trim, if equipped. 15. On the coupe install the rear quarter trim panel. 16. On the sedan perform the following procedure: 1. Install the upper rear quarter trim panel. 2. Install the center pillar upper trim panel. 17. Install the windshield upper garnish molding. 18. Install the coat hooks. 19. Install the sunshades. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair Rear Shelf: Service and Repair Trim Panel Replacement - Rear Window Shelf Removal Procedure 1. Fold down the rear seat backs. 2. On sedan perform the following: * Remove the upper quarter trim panels. * Remove the lower quarter trim panels. 3. On the coupe remove the quarter trim panel extensions. Refer to Trim Panel Replacement Rear Quarter. 4. Lift up and remove the bezels (2) for the child tether anchors. 5. Lift up and remove the bezel (1) for the center seat belt retractor. 6. Route the seat belts through the T-slots (4) in the rear window trim panel (3). 7. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 8. Remove the trim panel (3) from the rear shelf. Installation Procedure 1. Position the trim panel (3) in the rear shelf. 2. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 3. Route the seat belts through the T-slots (4) in the rear window trim panel (3). 4. Install the bezel (1) for the rear center seat belt retractor. Press the bezel (1) until fully engaged into the trim panel (3). 5. Install the bezels (2) for the child tether anchors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair > Page 7559 Press the bezels (2) until fully engaged into the trim panel (3). 6. On the coupe install the quarter trim panel extensions. Refer to Trim Panel Replacement - Rear Quarter. 7. On sedan perform the following: * Install the lower quarter trim panels. * Install the upper quarter trim panels. 8. Return the rear seat backs to their upright position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunshade screws (2). 2. Remove the sunshade (1). INSTALLATION PROCEDURE 1. Install the sunshade (1). 2. Install the sunshade screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 7564 Sun Visor: Removal and Replacement Sunshade Replacement Removal Procedure 1. Remove the sunshade screws (2). 2. Remove the sunshade (1). Installation Procedure 1. Install the sunshade (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the sunshade screws (2). Tighten the screws to 1.9 N.m (17 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement Trim Panel: Service and Repair Center Pillar Upper Trim Panel Replacement Center Pillar Upper Trim Panel Replacement Removal Procedure 1. Remove the front seat shoulder belt guide cover. 2. Remove the front seat shoulder belt guide bolt. 3. Pull the center pillar upper trim panel (1) outward at the roof in order to disengage the clips. 4. Remove the center pillar trim panel from the vehicle. Installation Procedure 1. Position the center pillar trim pane (1) in the vehicle. 2. Push the center pillar upper trim panel (1) in order to engage the clips. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the front seat shoulder belt guide bolt. Tighten the shoulder belt guide bolt to 41 N.m (30 lb ft). 4. Install the front seat shoulder belt guide cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7569 Trim Panel: Service and Repair Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Removal Procedure 1. Open the rear compartment lid. 2. Lift upward on the inner edge of the sill trim plate and remove the plate from the rear body panel. 3. Remove the spare tire cover retainer. 4. Remove the rear compartment spare tire cover. 5. Remove the cargo net, if equipped. 6. Remove the push-in retainers (2) near the tail lamps, if equipped. 7. Fold down the rear seat back. 8. Remove the push-in retainer from the left rear shock tower. 9. Fold the right section of the rear compartment trim panel toward the center of the compartment and remove it. Installation Procedure 1. Install the trim panel into the rear compartment. 2. Adjust the trim panel to the desired appearance. 3. Align the trim panel with the slots in the rear body panel, and press until the plate clips are fully engaged. 4. Install the rear compartment spare tire cover. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7570 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spare tire cover retainer. Tighten the retainer to 1.5 N.m (13 lb in). 6. Install the push-in retainers (2) near the tail lamps, if equipped. 7. Install the cargo net, if equipped. 8. Return the rear seat back to its upright position. 9. Install the push-in retainer to the left rear shock tower. 10. Close the rear compartment lid. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7571 Trim Panel: Service and Repair Garnish Molding Replacement GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR REMOVAL PROCEDURE 1. Start at the top of the windshield garnish molding (2). 2. Pull the garnish molding (2) firmly and evenly in order to disengage the retainers from the windshield pillar. 3. Remove the garnish molding (2) from the windshield pillar. 4. Pull the door weather strip away from the garnish molding (2). INSTALLATION PROCEDURE 1. Position the garnish molding (2) to the windshield pillar. 2. Align the garnish molding retainers to the openings in the windshield pillar (1). 3. Press the garnish molding (2) firmly and evenly to engage the retainers to the windshield pillar. 4. Reposition the door weather strip along the garnish molding (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7572 Trim Panel: Service and Repair Quarter Lower Rear Trim Panel Replacement Quarter Lower Rear Trim Panel Replacement Removal Procedure 1. Remove the rear seat cushion. 2. Remove the rear quarter upper trim panel. 3. Fold down the rear seat back. 4. Remove the push retainer (1) from the lower quarter trim panel (2). 5. Pull the trim panel (2 ) firmly and evenly in order to disengage the retainers from the lower quarter panel. 6. Remove the trim panel (2) from the lower quarter panel. Installation Procedure 1. Position the trim panel (2) to the lower quarter panel. 2. Align the trim panel retainers with the openings in the lower quarter panel. 3. Press the trim panel (2) firmly and evenly in order to engage the retainers to the lower quarter panel. 4. Install the push retainer (1) to the trim panel (2). 5. Return the rear seat back to its upright position. 6. Install the rear quarter upper trim panel. 7. Install the rear seat cushion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7573 Trim Panel: Service and Repair Center Pillar Upper Trim Panel Replacement Center Pillar Upper Trim Panel Replacement Removal Procedure 1. Remove the front seat shoulder belt guide cover. 2. Remove the front seat shoulder belt guide bolt. 3. Pull the center pillar upper trim panel (1) outward at the roof in order to disengage the clips. 4. Remove the center pillar trim panel from the vehicle. Installation Procedure 1. Position the center pillar trim pane (1) in the vehicle. 2. Push the center pillar upper trim panel (1) in order to engage the clips. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the front seat shoulder belt guide bolt. Tighten the shoulder belt guide bolt to 41 N.m (30 lb ft). 4. Install the front seat shoulder belt guide cover. Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Removal Procedure 1. Open the rear compartment lid. 2. Lift upward on the inner edge of the sill trim plate and remove the plate from the rear body panel. 3. Remove the spare tire cover retainer. 4. Remove the rear compartment spare tire cover. 5. Remove the cargo net, if equipped. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7574 6. Remove the push-in retainers (2) near the tail lamps, if equipped. 7. Fold down the rear seat back. 8. Remove the push-in retainer from the left rear shock tower. 9. Fold the right section of the rear compartment trim panel toward the center of the compartment and remove it. Installation Procedure 1. Install the trim panel into the rear compartment. 2. Adjust the trim panel to the desired appearance. 3. Align the trim panel with the slots in the rear body panel, and press until the plate clips are fully engaged. 4. Install the rear compartment spare tire cover. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spare tire cover retainer. Tighten the retainer to 1.5 N.m (13 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7575 6. Install the push-in retainers (2) near the tail lamps, if equipped. 7. Install the cargo net, if equipped. 8. Return the rear seat back to its upright position. 9. Install the push-in retainer to the left rear shock tower. 10. Close the rear compartment lid. Garnish Molding Replacement GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR REMOVAL PROCEDURE 1. Start at the top of the windshield garnish molding (2). 2. Pull the garnish molding (2) firmly and evenly in order to disengage the retainers from the windshield pillar. 3. Remove the garnish molding (2) from the windshield pillar. 4. Pull the door weather strip away from the garnish molding (2). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7576 1. Position the garnish molding (2) to the windshield pillar. 2. Align the garnish molding retainers to the openings in the windshield pillar (1). 3. Press the garnish molding (2) firmly and evenly to engage the retainers to the windshield pillar. 4. Reposition the door weather strip along the garnish molding (2). Quarter Lower Rear Trim Panel Replacement Quarter Lower Rear Trim Panel Replacement Removal Procedure 1. Remove the rear seat cushion. 2. Remove the rear quarter upper trim panel. 3. Fold down the rear seat back. 4. Remove the push retainer (1) from the lower quarter trim panel (2). 5. Pull the trim panel (2 ) firmly and evenly in order to disengage the retainers from the lower quarter panel. 6. Remove the trim panel (2) from the lower quarter panel. Installation Procedure 1. Position the trim panel (2) to the lower quarter panel. 2. Align the trim panel retainers with the openings in the lower quarter panel. 3. Press the trim panel (2) firmly and evenly in order to engage the retainers to the lower quarter panel. 4. Install the push retainer (1) to the trim panel (2). 5. Return the rear seat back to its upright position. 6. Install the rear quarter upper trim panel. 7. Install the rear seat cushion. Quarter Upper Trim Panel Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7577 Quarter Upper Trim Panel Replacement Removal Procedure 1. Pull out the top of the upper quarter trim panel. 2. Pull the trim panel (1) firmly and evenly in order to disengage the retainers from the upper quarter panel. 3. Remove the trim panel (1) from the upper quarter panel. Installation Procedure 1. Position the lower locating tabs on the trim panel (1) behind the lower quarter trim panel. 2. Align the trim panel retainers with the openings in the upper quarter panel. 3. Press the trim panel (1) firmly and evenly in order to engage the retainers to the upper quarter panel. Rear Compartment Sill Trim Plate Replacement Rear Compartment Sill Trim Plate Replacement Removal Procedure 1. Open the rear compartment. 2. Lift up from the inside edge of the sill trim plate in order to release the retainer. 3. Remove the rear compartment sill trim plate. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7578 1. Position the rear compartment sill trim plate to the slots in the rear body panel. 2. Install the rear compartment sill plate pressing into place until fully seated. 3. Close the rear compartment. Rear Compartment Trim Panel Replacement Rear Compartment Trim Panel Replacement Removal Procedure 1. Open the rear compartment lid. 2. Lift upward on the inner edge of the sill trim plate and remove the plate from the rear body panel. 3. Remove the spare tire cover retainer. 4. Remove the rear compartment spare tire cover. 5. Remove the cargo net, if equipped. 6. Remove the push-in retainers (2) near the tail lamps, if equipped. 7. Fold down the rear seat back. 8. Remove the push-in retainer from the left rear shock tower. 9. Fold the right section of the rear compartment trim panel toward the center of the compartment and remove it. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7579 1. Install the trim panel into the rear compartment. 2. Adjust the trim panel to the desired appearance. 3. Align the trim panel with the slots in the rear body panel, and press until the plate clips are fully engaged. 4. Install the rear compartment spare tire cover. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spare tire cover retainer. Tighten the retainer to 1.5 N.m (13 lb in). 6. Install the push-in retainers (2) near the tail lamps, if equipped. 7. Install the cargo net, if equipped. 8. Return the rear seat back to its upright position. 9. Install the push-in retainer to the left rear shock tower. 10. Close the rear compartment lid. Rear Quarter Trim Panel Replacement Rear Quarter Trim Panel Replacement Removal Procedure Tools Required J 38778 Door Trim Pad Clip Remover 1. Remove the rear split folding seat back. 2. Remove the coat hook. 3. Remove the front seat belt anchor bolt, and shoulder guide bolt. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7580 4. Use a J 38778 to remove the push in retainer (5) from the quarter panel extension (4). 5. Remove the quarter trim panel extension (4). 6. With a flat-bladed tool remove the seat belt escutcheon (6) form the trim panel (3). 7. Pull out the top of the quarter trim panel (3). 8. Pull the trim panel (3) firmly and evenly to disengage the retainers from the inner quarter panel (1). 9. Route the seat belt (7) through the opening in the trim panel (3). 10. Remove the trim panel (3) from the vehicle. Installation Procedure 1. Position the trim panel (3) into the vehicle. 2. Route the seat belt (7) through the opening in the trim panel (3). 3. Align the trim panel retainers with the openings in the inner quarter panel (1). 4. Press the trim panel (3) firmly and evenly in order to engage the retainers to the inner quarter panel (1). 5. Install the seat belt escutcheon (6) to the trim panel (3). 6. Install the quarter trim panel extension (4). 7. Install the push retainer (5) to the quarter trim panel extension. 8. Install the front seat belt anchor bolt, and shoulder guide bolt. 9. Install the coat hook. 10. Install the rear split folding seat back. Rear Window Shelf Trim Panel Replacement Rear Window Shelf Trim Panel Replacement Removal Procedure 1. Fold down the rear seat backs. 2. On sedan perform the following: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7581 * Remove the upper quarter trim panels. * Remove the lower quarter trim panels. 3. On the coupe remove the quarter trim panel extensions. Refer to Rear Quarter Trim Panel Replacement. 4. Lift up and remove the bezels (2) for the child tether anchors. 5. Lift up and remove the bezel (1) for the center seat belt retractor. 6. Route the seat belts through the T-slots (4) in the rear window trim panel (3). 7. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 8. Remove the trim panel (3) from the rear shelf. Installation Procedure 1. Position the trim panel (3) in the rear shelf. 2. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 3. Route the seat belts through the T-slots (4) in the rear window trim panel (3). 4. Install the bezel (1) for the rear center seat belt retractor. Press the bezel (1) until fully engaged into the trim panel (3). 5. Install the bezels (2) for the child tether anchors. Press the bezels (2) until fully engaged into the trim panel (3). 6. On the coupe install the quarter trim panel extensions. 7. On sedan perform the following: * Install the lower quarter trim panels. * Install the upper quarter trim panels. 8. Return the rear seat backs to their upright position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7582 Trim Panel Replacement - Rear Quarter Trim Panel Replacement - Rear Quarter Removal Procedure Tools Required J 38778 Door Trim Pad Clip Remover 1. Remove the rear split folding seat back. 2. Remove the coat hook. 3. Remove the front seat belt anchor bolt, and shoulder guide bolt. 4. Use a J 38778 to remove the pushing retainer (5) from the quarter panel extension (4). 5. Remove the quarter trim panel extension (4). 6. With a flat-bladed tool remove the seat belt escutcheon (6) form the trim panel (3). 7. Pull out the top of the quarter trim panel (3). 8. Pull the trim panel (3) firmly and evenly to disengage the retainers from the inner quarter panel (1). 9. Route the seat belt (7) through the opening in the trim panel (3). 10. Remove the trim panel (3) from the vehicle. Installation Procedure 1. Position the trim panel (3) into the vehicle. 2. Route the seat belt (7) through the opening in the trim panel (3). 3. Align the trim panel retainers with the openings in the inner quarter panel (1). 4. Press the trim panel (3) firmly and evenly in order to engage the retainers to the inner quarter panel (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7583 5. Install the seat belt escutcheon (6) to the trim panel (3). 6. Install the quarter trim panel extension (4). 7. Install the push retainer (5) to the quarter trim panel extension. 8. Install the front seat belt anchor bolt, and shoulder guide bolt. 9. Install the coat hook. 10. Install the rear split folding seat back. Trim Panel Replacement - Rear Quarter Lower Trim Panel Replacement - Rear Quarter Lower Removal Procedure 1. Remove the rear seat cushion. 2. Remove the rear quarter upper trim panel. 3. Fold down the rear seat back. 4. Remove the push retainer (1) from the lower quarter trim panel (2). 5. Pull the trim panel (2 ) firmly and evenly in order to disengage the retainers from the lower quarter panel. 6. Remove the trim panel (2) from the lower quarter panel. Installation Procedure 1. Position the trim panel (2) to the lower quarter panel. 2. Align the trim panel retainers with the openings in the lower quarter panel. 3. Press the trim panel (2) firmly and evenly in order to engage the retainers to the lower quarter panel. 4. Install the push retainer (1) to the trim panel (2). 5. Return the rear seat back to its upright position. 6. Install the rear quarter upper trim panel. 7. Install the rear seat cushion. Trim Panel Replacement - Rear Quarter Upper Trim Panel Replacement - Rear Quarter Upper Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7584 1. Pull out the top of the upper quarter trim panel. 2. Pull the trim panel (1) firmly and evenly in order to disengage the retainers from the upper quarter panel. 3. Remove the trim panel (1) from the upper quarter panel. Installation Procedure 1. Position the lower locating tabs on the trim panel (1) behind the lower quarter trim panel. 2. Align the trim panel retainers with the openings in the upper quarter panel. 3. Press the trim panel (1) firmly and evenly in order to engage the retainers to the upper quarter panel. Trim Panel Replacement - Rear Window Shelf Trim Panel Replacement - Rear Window Shelf Removal Procedure 1. Fold down the rear seat backs. 2. On sedan perform the following: * Remove the upper quarter trim panels. * Remove the lower quarter trim panels. 3. On the coupe remove the quarter trim panel extensions. Refer to Trim Panel Replacement Rear Quarter. 4. Lift up and remove the bezels (2) for the child tether anchors. 5. Lift up and remove the bezel (1) for the center seat belt retractor. 6. Route the seat belts through the T-slots (4) in the rear window trim panel (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7585 7. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 8. Remove the trim panel (3) from the rear shelf. Installation Procedure 1. Position the trim panel (3) in the rear shelf. 2. Route the center seat belts and bezel (1) through the opening in the trim panel (3). 3. Route the seat belts through the T-slots (4) in the rear window trim panel (3). 4. Install the bezel (1) for the rear center seat belt retractor. Press the bezel (1) until fully engaged into the trim panel (3). 5. Install the bezels (2) for the child tether anchors. Press the bezels (2) until fully engaged into the trim panel (3). 6. On the coupe install the quarter trim panel extensions. Refer to Trim Panel Replacement - Rear Quarter. 7. On sedan perform the following: * Install the lower quarter trim panels. * Install the upper quarter trim panels. 8. Return the rear seat backs to their upright position. Trim Panel Replacement - Upper Center Pillar Trim Panel Replacement - Upper Center Pillar Removal Procedure 1. Remove the front seat shoulder belt guide cover. 2. Remove the front seat shoulder belt guide bolt. 3. Pull the center pillar upper trim panel (1) outward at the roof in order to disengage the clips. 4. Remove the center pillar trim panel from the vehicle. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Center Pillar Upper Trim Panel Replacement > Page 7586 1. Position the center pillar trim pane (1) in the vehicle. 2. Push the center pillar upper trim panel (1) in order to engage the clips. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the front seat shoulder belt guide bolt. Tighten the shoulder belt guide bolt to 41 N.m (30 lb ft). 4. Install the front seat shoulder belt guide cover. Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Removal Procedure 1. Start at the top of the windshield garnish molding (2). 2. Pull the garnish molding (2) firmly and evenly in order to disengage the retainers from the windshield pillar. 3. Remove the garnish molding (2) from the windshield pillar. 4. Pull the door weather strip away from the garnish molding (2). Installation Procedure 1. Position the garnish molding (2) to the windshield pillar. 2. Align the garnish molding retainers to the openings in the windshield pillar (1). 3. Press the garnish molding (2) firmly and evenly to engage the retainers to the windshield pillar. 4. Reposition the door weather strip along the garnish molding (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures Door Lock Cylinder: Procedures LOCK CYLINDER REPLACEMENT - DOOR REMOVAL PROCEDURE 1. Raise the window to the full UP position. 2. Remove the front door trim panel. 3. Remove the water deflector in order to access the lock cylinder. 4. Remove the lower window channel retainer (2). 5. Remove the lock cylinder retaining clip (1). 6. Remove the lock rod from the lock cylinder (3). 7. Remove the lock cylinder (3) from the door. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7593 1. Install the lock rod to the door lock cylinder (3). 2. Install the lock cylinder (3). 3. Install the lock cylinder retaining clip (1). 4. Install the lower window channel retainer (2). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7594 Door Lock Cylinder: Removal and Replacement Door Lock Cylinder Replacement Removal Procedure 1. Raise the window to the full UP position. 2. Remove the front door trim panel. 3. Remove the water deflector in order to access the lock cylinder. 4. Remove the lower window channel retainer (2). 5. Remove the lock cylinder retaining clip (1). 6. Remove the lock rod from the lock cylinder (3). 7. Remove the lock cylinder (3) from the door. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 7595 1. Install the lock rod to the door lock cylinder (3). 2. Install the lock cylinder (3). 3. Install the lock cylinder retaining clip (1). 4. Install the lower window channel retainer (2). 5. Install the water deflector. 6. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations Right Front I/P Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations > Page 7599 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7604 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7605 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 7606 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REMOVAL PROCEDURE 1. Insert a small flat-bladed tool between the 2 halves of the transmitter case (6,4) at the slot provided near the key ring (5) hole. 2. Twist the tool in order to open the case. 3. Remove the battery (2). INSTALLATION PROCEDURE 1. Install the battery (2) with the positive (+) side facing down. Use one 3-volt CR2032 battery or the equivalent. 2. Ensure the transmitter case seal is in the proper position. 3. Align the 2 halves of the transmitter case (6,4). 4. Snap the 2 halves of the transmitter case together. 5. Test the operation of the transmitter. IMPORTANT: Normal battery life is approximately 2 years. Replace the batteries when the range of the transmitter begins to decrease significantly to less than approximately 7 m (23 ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams Power Door Lock Actuator: Diagrams Door Lock Actuator - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 7616 Door Lock Actuator - Front Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 7617 Door Lock Actuator - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Page 7618 Door Lock Actuator - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Service and Repair Power Door Lock Relay: Service and Repair LOCK RELAY REPLACEMENT - POWER DOOR REMOVAL PROCEDURE 1. Remove the passenger carpet retainer. 2. Remove enough of the carpet to access the door lock relay (1) located on the passenger hinge pillar (2). 3. Pull the relay (1) away from the hinge pillar (2) disengaging the rosebud retainer. 4. Disconnect the electrical connector (3) from the relay (1). 5. Remove the relay (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the relay (1) into the vehicle. 2. Connect the electrical connector (3) to the relay (1). 3. Attach the rosebud retainer on the relay (1) to the hinge pillar (2). 4. Install the carpet to a desired appearance. 5. Install the passenger carpet retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7625 Door Lock Switch - Front Passenger With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7626 Door Lock Switch - Driver Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 7627 Door Lock Switch - Front Passenger Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures POWER DOOR LOCK SWITCH REPLACEMENT REMOVAL PROCEDURE 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. INSTALLATION PROCEDURE 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 7630 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement Removal Procedure 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. Installation Procedure 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Rear Compartment Lid Lock Cylinder Replacement Removal Procedure 1. Remove the compartment lid applique. 2. Remove the compartment lid latch cable assembly (8) from behind the lid lock. Spread the black plastic housing and pull down. 3. For the Cavalier only, remove the compartment lid lock cylinder retainer (4). 4. For the Sunfire only, drill out the rivets. 5. Remove the compartment lid lock cylinder (1). Installation Procedure 1. Install the compartment lid lock cylinder (1). 2. For the Cavalier only, install the compartment lid lock cylinder retainer (4). 3. For the Sunfire only, install the spacer and the lock rivets. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair > Page 7634 4. Install the compartment lid lock cable assembly (8). 5. Install the compartment lid applique. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 7644 Memory Positioning Systems: Description and Operation Vehicle Personalization PERSONALIZATION CHIME LEVEL ADJUSTMENT - RDS RADIOS ONLY In order to adjust the chime level, perform the following steps: 1. Turn the ignition ON. 2. Turn the radio OFF. 3. Press and hold the radio push-button 6 until either LOUD or NORMAL appears on the radio display. The chime sounds 3 times for each volume change. 4. To toggle the setting, press and hold the radio push-button 6 again. PROGRAMMING FEATURES WITH TECH 2 Enter Programming To enter Programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select F0: Body Control Module 5. Select F2: Special Functions 6. Select F2: Personalization Setting Options Select an option with the UP/DOWN ARROW keys. The selected option will be highlighted. Use the SIDE-TO-SIDE ARROW keys to activate or deactivate the highlighted options, an ASTERISK will be displayed when an option has been ACTIVATED. Use the SOFT keys to save the selected options or use the EXIT key to leave the options unchanged. After all options have been selected press the SOFT key to continue. The following is a list of the selectable options: 1. Remote Function Activation (RFA) Audible Unlock Feedback 2. RFA Audible Lock Feedback 3. RFA Visual Feedback 4. Pre-Alarm Horn Chirp Additional Information Refer to Audible Warnings Description and Operation in Instrument Panel, Gages, and Console for more information about the chime. Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about RFA. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 7645 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. For more information on driver personalization features for this vehicle, refer to Driver Personalization. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Driver Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7649 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 7650 Outside Rearview Mirror Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). INSTALLATION PROCEDURE 1. Install the switch (2) to the trim panel (1). 2. Begin tightening the set screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 7653 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Removal Procedure 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). Installation Procedure 1. Install the switch (2) to the trim panel (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Begin tightening the set screw (3). Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 7663 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 7669 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7679 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7680 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7681 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7682 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 7685 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7688 WA111B/95 - WA303D/25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7689 WA303D/25 - WA379E/86 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7690 WA379E/86 - WA382E/11 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7691 WA382E/11 - WA408G/44 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7692 WA408G/44 - WA519F/12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7693 WA519F/12 - WA5322/33 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7694 WA5322/33 - WA534F/54 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7695 WA534F/54 - WA5456/43 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7696 WA5456/43 - WA7156/46 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7697 WA722J/25 - WA722J/25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7698 WA722J/25 - WA800J/98 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7699 WA800J/98 - WA805K/62 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7700 WA805K/62 - WA811K/87 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7701 WA811K/87 - WA812K/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7702 WA812K/88 - WA812K/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7703 WA812K/88 - WA815K/91 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7704 WA815K/91 - WA817K/63 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7705 WA817K/63 - WA817K/63 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7706 WA817K/63 - WA822K/97 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7707 WA822K/97 - WA8554/40 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7708 WA8554/40 - WA8554/40 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7709 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7710 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7711 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7712 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7713 WA8555/41 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7714 WA8624/50 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7715 WA8624/50 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7716 WA8743/28 - WA885K/70 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7717 WA885K/70 - WA913L/56 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7718 WA913L/56 - WA9260/74 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7719 WA9260/74 - WA9260/74 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7720 WA9260/74 - WA926L/59 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7721 WA926L/59 - WA929L/15 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7722 WA929L/15 - WA931L/68 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7723 WA931L/68 - WA9417/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7724 WA9417/88 - WA9539/47 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7725 WA9539/47 - WA9566/13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7726 WA9566/13 - WA964L/29 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7727 WA964L/29 - WA9792/39 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7728 WA9800/77 - WA994L/67 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7729 WA994L/67 - WA994L/67 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7730 WA994L/67 - WA994L/67 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7731 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7732 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7733 Paint: Application and ID Parts ID Label Location The vehicle service parts identification label is located in the rear compartment under the spare tire cover. The label is used to help identify the vehicle original parts and options. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7734 Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7735 WA111B/95 - WA303D/25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7736 WA303D/25 - WA379E/86 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7737 WA379E/86 - WA382E/11 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7738 WA382E/11 - WA408G/44 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7739 WA408G/44 - WA519F/12 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7740 WA519F/12 - WA5322/33 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7741 WA5322/33 - WA534F/54 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7742 WA534F/54 - WA5456/43 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7743 WA5456/43 - WA7156/46 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7744 WA722J/25 - WA722J/25 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7745 WA722J/25 - WA800J/98 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7746 WA800J/98 - WA805K/62 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7747 WA805K/62 - WA811K/87 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7748 WA811K/87 - WA812K/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7749 WA812K/88 - WA812K/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7750 WA812K/88 - WA815K/91 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7751 WA815K/91 - WA817K/63 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7752 WA817K/63 - WA817K/63 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7753 WA817K/63 - WA822K/97 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7754 WA822K/97 - WA8554/40 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7755 WA8554/40 - WA8554/40 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7756 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7757 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7758 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7759 WA8555/41 - WA8555/41 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7760 WA8555/41 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7761 WA8624/50 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7762 WA8624/50 - WA8624/50 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7763 WA8743/28 - WA885K/70 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7764 WA885K/70 - WA913L/56 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7765 WA913L/56 - WA9260/74 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7766 WA9260/74 - WA9260/74 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7767 WA9260/74 - WA926L/59 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7768 WA926L/59 - WA929L/15 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7769 WA929L/15 - WA931L/68 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7770 WA931L/68 - WA9417/88 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7771 WA9417/88 - WA9539/47 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7772 WA9539/47 - WA9566/13 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7773 WA9566/13 - WA964L/29 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7774 WA964L/29 - WA9792/39 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7775 WA9800/77 - WA994L/67 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7776 WA994L/67 - WA994L/67 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7777 WA994L/67 - WA994L/67 Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 7778 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Parts ID Label Location The vehicle service parts identification label is located in the rear compartment under the spare tire cover. The label is used to help identify the vehicle original parts and options. Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The base coat/clear coat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Service Part Identification Label in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation Radiator Support: Description and Operation Radiator Support Description The radiator support assembly consists of 4 major upper components and 5 major lower components. The following components are preassembled in order to aid in the alignment of the front structure: * The center reinforcement * The left extensions * The right extensions The upper support is serviced separately in order to provide efficient installation. The lower support is held in place with 6 bolts. The lower support attaches to the 4 brackets that are welded to the lower rails. The brackets are available either as a component of the lower rail service assembly or separately. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations Right Front I/P Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 7786 Door Lock Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Service and Repair Power Door Lock Relay: Service and Repair LOCK RELAY REPLACEMENT - POWER DOOR REMOVAL PROCEDURE 1. Remove the passenger carpet retainer. 2. Remove enough of the carpet to access the door lock relay (1) located on the passenger hinge pillar (2). 3. Pull the relay (1) away from the hinge pillar (2) disengaging the rosebud retainer. 4. Disconnect the electrical connector (3) from the relay (1). 5. Remove the relay (1) from the vehicle. INSTALLATION PROCEDURE 1. Position the relay (1) into the vehicle. 2. Connect the electrical connector (3) to the relay (1). 3. Attach the rosebud retainer on the relay (1) to the hinge pillar (2). 4. Install the carpet to a desired appearance. 5. Install the passenger carpet retainer. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations Sunroof Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7793 Sunroof / Moonroof Module: Diagrams Sunroof Control Module, C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7794 Sunroof Control Module C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Locations > Page 7795 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Close the sunroof. 2. Remove the headliner. 3. Remove the tie wraps securing the power sunroof control module wire harness to the drive and return tubes. 4. Release the retainers for the power sunroof control module by sliding the control module (2) towards the middle of the vehicle. 5. Disconnect the wire harness electrical connectors from the power sunroof control module (2). INSTALLATION PROCEDURE 1. Connect the wire harness connectors to the power sunroof control module (2). 2. Engage the power sunroof control module retainers by sliding the control module (2) towards the left side of the vehicle. 3. Install the tie wraps to secure the power sunroof control module wire harness to the drive and return tubes. 4. Install the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair SUNROOF SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Place the sunroof into the full vent position. 2. Place the sunroof sunshade (1) into the open position. 3. Push the guide (2) on the left front sunroof sunshade toward the middle of the vehicle. 4. Disengage the guide from the track on the left front sunroof sunshade. 5. Slide the sunroof sunshade into the closed position. 6. Push the guide on the left rear sunroof sunshade toward the middle of the vehicle. 7. Disengage the guide on the left rear sunroof sunshade. 8. Remove the sunroof sunshade (1) from the vehicle using the following procedure: 8.1. Pull the sunroof sunshade towards the left side of the vehicle in order to disengage the guides on the right side sunroof sunshade. 8.2. Pull the sunroof sunshade out between the glass panel and the roof. INSTALLATION PROCEDURE 1. With the sunroof in the full vent position, install the sunroof sunshade (1) into the vehicle between the roof and the glass panel. 2. Position the guides on the right side sunroof sunshade to the guide rail. 3. Engage the guide on the left rear sunroof sunshade to the guide rail using a flat bladed tool. 4. Slide the sunroof sunshade to the open position. 5. Engage the guide on the left front sunroof sunshade to the guide rail. 6. Check for proper operation of the sunshade. 7. Close the sunroof. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair Sunroof / Moonroof Cable: Service and Repair SUNROOF DRIVE CABLE REPLACEMENT TOOLS REQUIRED J 38043 Sunroof T-wrench REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Use J 38043 in the sunroof motor slot and manually lower the sunroof guides to the closed position. 3. Disconnect the sunroof motor/actuator. 4. From above the vehicle, remove the left and the right cable retainer fasteners from the sunroof. 5. Remove the retainers. 6. Lift the sunroof drive cable end out of the guide assembly. 7. Hold the sunroof drive cable guide tubes in position. 8. Pull the sunroof drive cables out of the guide tubes. INSTALLATION PROCEDURE 1. Hold the sunroof drive cable tubes in position. IMPORTANT: Do not kink the cables. Replace the cables if they are kinked. Replace the cables in pairs. Sunroof cables have a flexible sealer at the tray assembly. Ensure that the seal is not broken during cable removal or installation. 2. Push the sunroof drive cables into the guide tubes. 3. Engage the sunroof drive cables into the guide assemblies. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Service and Repair > Page 7804 4. Install the sunroof drive cable retainers. Seat the cable housing flair firmly into the module tray groove. 5. Connect the sunroof motor/actuator. 6. Install the sunroof window. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation SUNROOF LIMIT SWITCHES The sunroof limit switches track the position of the sunroof glass through two limit switches: - Soft Stop limit switch through the sunroof limit switch soft stop signal circuit - Vent Stop limit switch through the sunroof limit switch range signal circuit The sunroof control module monitors the limit switches and based on the input combinations, determines the position of the sunroof glass. As a sunroof limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module monitors both sunroof switch input requests and based on the sunroof limit switch input combinations, will control an output to the sunroof motor, to drive the sunroof glass to the requested position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely Sunroof / Moonroof Motor: Customer Interest Body - Sunroof Won't Open/Close Completely Bulletin No.: 03-08-67-009A Date: March 08, 2004 TECHNICAL Subject: Sunroof Will Not Open or Close Completely (Replace Sunroof Motor) Models: 1998-2004 Chevrolet Cavalier 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Grand Am 1998-2004 Pontiac Sunfire Supercede: This bulletin is being revised to change the part number. Please discard Corporate Bulletin Number 03-08-67-009 (Section 08 - Body and Accessories) Condition Some customers may comment that the sunroof will not open or will not close completely. Cause This condition may be due to the sunroof motor. Follow the procedure below for diagnostics. Sunroof Motor Diagnosis 1. Remove the headliner as necessary. 2. Jumper Pin # 1 and Pin # 8 on the sunroof express module. If more access is needed, push the module towards the motor and unlock it from the bracket. Refer to the Illustration above. Note: Avoid operating the sunroof glass to the full open position. Since the limit switch has a jumper across it, there will be no indication to the sunroof module to stop the glass at the full open soft stop. The glass can slide past the full open position, possibly damaging the sunroof assembly and/or the roof. 3. With the ignition ON, push the sunroof switch to the close position to fully seat the sunroof. If this action fully closes the sunroof, replace the sunroof motor only. Refer to the Sunroof Motor Replacement below. If this action does not fully close the sunroof, go to Diagnostic Starting Point-Roof in the service manual. 4. Remove the jumper and re-lock the sunroof express module back into its bracket. Sunroof Motor Replacement Service Procedure Note: This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7816 timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly. 1. Clip the tie straps and remove the express module by sliding it towards the motor to unlock it from the slots provided in the module. 2. Disconnect the wire harness from the express module, power supply, and switch. 3. remove the sunroof motor/actuator bolts(2) from the sunroof motor/actuator. 4. Remove the sunroof motor/actuator from the sunroof module. 5. Remove the sunroof glass. 6. Make sure the sunroof lift arms are aligned by inserting a pin in the front sunroof glass attachment hole to the lift arm cam. If you can insert a large paper clip through the two, it is aligned. Refer to the illustration above. 7. If the arms are not aligned, push the arms with a screwdriver at the location shown. Refer to the illustration above. Important: Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position. 8. Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by preforming the following steps: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7817 8.1. The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. Refer to the illustration above. 8.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify that all timing marks are aligned. 9. Position the sunroof motor/actuator to the sunroof module. 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 coatings affect fastener torque and joint clamping force and may damage the fasteners. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the sunroof motor/actuator. Tighten Tighten the sunroof motor/actuator to 3 N.m (27 lb in). 11. Connect the wire harness connectors to the express module. Slide the express module into the slots and lock it. Reconnect the power supply and the switch to the express module. Secure the wire harness to the drive tube and return tube with tie wraps. 12. Install the headliner as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7818 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely Sunroof / Moonroof Motor: All Technical Service Bulletins Body - Sunroof Won't Open/Close Completely Bulletin No.: 03-08-67-009A Date: March 08, 2004 TECHNICAL Subject: Sunroof Will Not Open or Close Completely (Replace Sunroof Motor) Models: 1998-2004 Chevrolet Cavalier 1999-2003 Oldsmobile Alero 1998-2003 Pontiac Grand Am 1998-2004 Pontiac Sunfire Supercede: This bulletin is being revised to change the part number. Please discard Corporate Bulletin Number 03-08-67-009 (Section 08 - Body and Accessories) Condition Some customers may comment that the sunroof will not open or will not close completely. Cause This condition may be due to the sunroof motor. Follow the procedure below for diagnostics. Sunroof Motor Diagnosis 1. Remove the headliner as necessary. 2. Jumper Pin # 1 and Pin # 8 on the sunroof express module. If more access is needed, push the module towards the motor and unlock it from the bracket. Refer to the Illustration above. Note: Avoid operating the sunroof glass to the full open position. Since the limit switch has a jumper across it, there will be no indication to the sunroof module to stop the glass at the full open soft stop. The glass can slide past the full open position, possibly damaging the sunroof assembly and/or the roof. 3. With the ignition ON, push the sunroof switch to the close position to fully seat the sunroof. If this action fully closes the sunroof, replace the sunroof motor only. Refer to the Sunroof Motor Replacement below. If this action does not fully close the sunroof, go to Diagnostic Starting Point-Roof in the service manual. 4. Remove the jumper and re-lock the sunroof express module back into its bracket. Sunroof Motor Replacement Service Procedure Note: This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7824 timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly. 1. Clip the tie straps and remove the express module by sliding it towards the motor to unlock it from the slots provided in the module. 2. Disconnect the wire harness from the express module, power supply, and switch. 3. remove the sunroof motor/actuator bolts(2) from the sunroof motor/actuator. 4. Remove the sunroof motor/actuator from the sunroof module. 5. Remove the sunroof glass. 6. Make sure the sunroof lift arms are aligned by inserting a pin in the front sunroof glass attachment hole to the lift arm cam. If you can insert a large paper clip through the two, it is aligned. Refer to the illustration above. 7. If the arms are not aligned, push the arms with a screwdriver at the location shown. Refer to the illustration above. Important: Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position. 8. Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by preforming the following steps: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7825 8.1. The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. Refer to the illustration above. 8.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify that all timing marks are aligned. 9. Position the sunroof motor/actuator to the sunroof module. 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 coatings affect fastener torque and joint clamping force and may damage the fasteners. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 10. Install the sunroof motor/actuator. Tighten Tighten the sunroof motor/actuator to 3 N.m (27 lb in). 11. Connect the wire harness connectors to the express module. Slide the express module into the slots and lock it. Reconnect the power supply and the switch to the express module. Secure the wire harness to the drive tube and return tube with tie wraps. 12. Install the headliner as necessary. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 03-08-67-009A > Mar > 04 > Body - Sunroof Won't Open/Close Completely > Page 7826 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 7827 Sunroof Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 7828 Sunroof / Moonroof Motor: Description and Operation SUNROOF MOTOR The sunroof has a bi-directional motor. When the motor is not operating both circuits are grounded. When the motor drives the sunroof glass in the direction from the closed to vent or vent to open position, the following occurs: - Voltage is supplied to the sunroof motor open circuit. - Ground is maintained to the sunroof motor close circuit. When the motor drives the sunroof in the direction from the open to vent or vent to closed position, the following occurs: - Voltage is supplied to the sunroof motor close circuit. - Ground is maintained to the sunroof motor open circuit. The sunroof control module is equipped with a timer circuit which stops the operation of the sunroof motor after 8 seconds. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 7829 Sunroof / Moonroof Motor: Service and Repair SUNROOF MOTOR/ACTUATOR REPLACEMENT REMOVAL PROCEDURE NOTE: This sunroof system is timed from the factory so that the sunroof actuator automatically shuts off when the window panel reaches a certain position. Be careful not to disrupt this factory timing when removing the sunroof actuator from the sunroof module. Disrupting the factory timing may cause damage to the sunroof system. Close the window panel whenever you remove the sunroof actuator from the sunroof module assembly. 1. Remove the headliner as necessary. 2. Disconnect the wire harnesses from the express module (8). 3. Remove the tie wraps securing the wire harness to the drive and return tubes (5, 6). 4. If the sunroof glass panel is not fully closed complete the following steps. 4.1. Locate the allen head screw on the drive gear of the sunroof motor/actuator (1). The allen head screw is accessible with the sunroof motor/actuator in place. 4.2. Remove the red retainer from the allen head screw using a small flat-blade tool, if equipped. 4.3. Turn the allen head screw until the sunroof glass panel is fully closed. You may need to apply a significant amount of force to move the sunroof actuator with the allen wrench. 4.4. Relieve the pressure on the sunroof motor/actuator by backing off the allen screw approximately 15 degrees. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 7830 IMPORTANT: The sunroof motor/actuator cannot be reused if this procedure is followed. 5. Remove the sunroof motor/actuator bolts (2) from the sunroof motor/actuator. 6. Disconnect the wire harness from the connector (1) on the sunroof motor/actuator. 7. Remove the sunroof motor/actuator from the sunroof module. INSTALLATION PROCEDURE 1. Verify that the original sunroof motor/actuator or the new sunroof motor/actuator is timed to the closed position by preforming the following steps. 1.1. The hole in the large timing gear (3), the notch in the disk (2) below the drive gear and the scribe mark (1) on the drive gear should all be in line with each other. 1.2. If the actuator is not timed to the closed position, connect the switch, headliner harness and express module to the sunroof motor/actuator and run the actuator to the closed position. Verify all timing marks are aligned. IMPORTANT: Before you install a new sunroof motor/actuator or re-install the old actuator to the sunroof module, ensure that the actuator is timed to the closed position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 7831 2. Connect the wire harness to connector (1) on the sunroof motor/actuator. 3. Position the sunroof motor/actuator to the sunroof module. 4. Install the sunroof actuator bolts (2) to the sunroof motor/actuator. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof motor/actuator bolts to 3 N.m (27 lb in). 5. Connect the wire harness connectors to the express module (8), and secure the wire harness to the drive tube and return tube (5, 6) with tie wraps. 6. Install the headliner as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Dome Lamp And Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7835 Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 7838 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. Installation Procedure 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Hose Replacement - Front SUNROOF DRAIN HOSE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the headliner as required. 2. Disconnect the drain hose drain port (1) connection from the sunroof module. 3. Cut through the sealer that is located inside the bottom of the windshield pillar in order to loosen the drain hose (1). Use a stiff rod bent at 90 degrees. 4. Remove the sunroof drain hose (1) from the windshield pillar. INSTALLATION PROCEDURE 1. Route the sunroof front drain hose (1) through the windshield pillar and into the drain hole. The drain hose is located near the door hinges. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7843 2. Connect the sunroof front drain hose drain port (1) connection to the sunroof module. 3. Apply sealer to the inside bottom of the windshield pillar and around the sunroof front drain hose (1). 4. Install the headliner. Sunroof Drain Hose Replacement - Rear SUNROOF DRAIN HOSE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the headliner. 2. Pull back the trunk carpeting away from the sides of the trunk to expose the sun roof drain hose (1). 3. Pull the outlet out of the quarter panel drain hole. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7844 4. Separate the outlet from the sunroof drain hose. 5. Release the sunroof drain hose from the retaining clip along the quarter panel. 6. Disconnect the sunroof drain hose (1) from the sun roof rear drain port. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7845 7. Release the sunroof drain hose from the retaining clip along the rear pillar. 8. Remove the rear sunroof drain hose through the rear compartment access hole, located between the seat belt retractor and the rear window. INSTALLATION PROCEDURE 1. Install the sunroof drain hose into the rear compartment through the access hole. 2. Press the sunroof drain hose into the retaining clip along the rear pillar. 3. Connect the sunroof drain hose (1) to the sunroof rear drain port. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7846 4. Press the sunroof drain hose into the retaining clip along the quarter panel. 5. Connect the sunroof drain hose to the drain hose outlet. 6. Press the sunroof drain hose (1) outlet into the quarter panel drain hole. 7. Check the sunroof drain hose for play. Secure the drain hose to the quarter panel or roof with 3M(TM) double sided tape P/N 06377 or equivalent, to prevent rattles. 8. Place the rear compartment trim back to the original position. 9. Install the headliner. Sunroof Drain Inspection and Cleaning Sunroof Drain Inspection and Cleaning Drain Hose Routing A sunroof drain trough encircles the sunroof glass panel and water drains off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the glass panel and directs water into the trough. 1. Ensure that the front sunroof drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. Ensure no kinks in the hoses exist. Replace any torn or cracked hoses. 2. Ensure that the rear sunroof drain hoses route through the rear pillars and out of the rocker panel. Ensure that the rear hoses are correctly routed in the metal roof slot and taped in place. Replace any torn or cracked hoses. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7847 Plugged Drain Hose If a waterleak occurs, check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. 3. Use compressed air, 240 kPa (35 psi) or less to blow out any plugged drain hose. 4. Test the system again. 5. If the hose remains plugged, ensure it is correctly routed. Verify that no kinks exist in the hose. 6. Remove any plugged hoses. 7. Remove the blockage using the following steps: 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air to blow out any remaining material. 3. Install the hose. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose: 1. Open the sunroof glass panel. 2. Withdraw the headliner from around the sunroof module. 3. Remove the power sunroof switch. 4. Lower the headliner as needed. Refer to Headlining Trim Panel Replacement in Interior Trim. 5. Connect any disconnected hoses. 6. Ensure the rear drain hoses are properly routed in the metal roof slot and taped in place. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7848 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. Remove the headliner as required. 2. Disconnect the drain hose drain port (1) connection from the sunroof module. 3. Cut through the sealer that is located inside the bottom of the windshield pillar in order to loosen the drain hose (1). Use a stiff rod bent at 90 degrees. 4. Remove the sunroof drain hose (1) from the windshield pillar. Installation Procedure 1. Route the sunroof front drain hose (1) through the windshield pillar and into the drain hole. The drain hose is located near the door hinges. 2. Connect the sunroof front drain hose drain port (1) connection to the sunroof module. 3. Apply sealer to the inside bottom of the windshield pillar and around the sunroof front drain hose (1). 4. Install the headliner. Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Removal Procedure 1. Remove the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7849 2. Pull back the trunk carpeting away from the sides of the trunk to expose the sun roof drain hose (1). 3. Pull the outlet out of the quarter panel drain hole. 4. Separate the outlet from the sunroof drain hose. 5. Release the sunroof drain hose from the retaining clip along the quarter panel. 6. Disconnect the sunroof drain hose (1) from the sun roof rear drain port. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7850 7. Release the sunroof drain hose from the retaining clip along the rear pillar. 8. Remove the rear sunroof drain hose through the rear compartment access hole, located between the seat belt retractor and the rear window. Installation Procedure 1. Install the sunroof drain hose into the rear compartment through the access hole. 2. Press the sunroof drain hose into the retaining clip along the rear pillar. 3. Connect the sunroof drain hose (1) to the sunroof rear drain port. 4. Press the sunroof drain hose into the retaining clip along the quarter panel. 5. Connect the sunroof drain hose to the drain hose outlet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 7851 6. Press the sunroof drain hose (1) outlet into the quarter panel drain hole. 7. Check the sunroof drain hose for play. Secure the drain hose to the quarter panel or roof with 3M(TM) double sided tape P/N 06377 or equivalent, to prevent rattles. 8. Place the rear compartment trim back to the original position. 9. Install the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations Sunroof Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7855 Sunroof / Moonroof Module: Diagrams Sunroof Control Module, C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7856 Sunroof Control Module C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Locations > Page 7857 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Close the sunroof. 2. Remove the headliner. 3. Remove the tie wraps securing the power sunroof control module wire harness to the drive and return tubes. 4. Release the retainers for the power sunroof control module by sliding the control module (2) towards the middle of the vehicle. 5. Disconnect the wire harness electrical connectors from the power sunroof control module (2). INSTALLATION PROCEDURE 1. Connect the wire harness connectors to the power sunroof control module (2). 2. Engage the power sunroof control module retainers by sliding the control module (2) towards the left side of the vehicle. 3. Install the tie wraps to secure the power sunroof control module wire harness to the drive and return tubes. 4. Install the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment 1. Open the sunshade (3). 2. Close the sunroof window. 3. Loosen the adjusting screws. 4. Adjust the corners of the glass panel (3) using the following guidelines: * Adjust the front of the sunroof window (2) flush to 1 mm (0.04 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window (1) flush to 1 mm (0.04 in) above the top surface of the roof panel. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the sunroof window adjustment screws. Tighten the sunroof window adjusting screws to 4 N.m (35 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 7861 Sunroof / Moonroof Panel: Service and Repair SUNROOF WINDOW REPLACEMENT REMOVAL PROCEDURE 1. Open the sunshade (1). 2. Close the sunroof window. 3. Remove the sunroof window screws (2) from the sunroof track. 4. Remove the sunroof window from the roof opening. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 7862 1. Install the sunroof window into the roof opening with the sunroof logo facing rearward. 2. Install the sunroof window screws (2) to the sunroof track. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the sunroof window screws to 4 N.m (35 lb in). 3. Check and adjust the sunroof window as necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF SEAL/MOLDING REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Remove the weatherstrip by pulling the weatherstrip (1) away from the glass panel. INSTALLATION PROCEDURE 1. Align the butt joint with the center of the sunroof window on the passenger side of the vehicle. 2. Work the weatherstrip into the channel in the glass panel frame. Continue to work the weatherstrip (1) until the weatherstrip is firmly press fit into the channel. Install the weatherstrip around the entire sunroof glass panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 7867 3. Install the sunroof window. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 7868 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement Sunroof Seal/Molding Replacement Removal Procedure 1. Remove the sunroof window. 2. Remove the weatherstrip by pulling the weatherstrip (1) away from the glass panel. Installation Procedure 1. Align the butt joint with the center of the sunroof window on the passenger side of the vehicle. 2. Work the weatherstrip into the channel in the glass panel frame. Continue to work the weatherstrip (1) until the weatherstrip is firmly press fit into the channel. Install the weatherstrip around the entire sunroof glass panel. 3. Install the sunroof window. Roof Side Rail Weatherstrip Replacement Roof Side Rail Weatherstrip Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 7869 1. Pull off the roof auxiliary weatherstrip (2) from the roof flange beginning from the front pillar weatherstrip. 2. Use a flat-bladed took to disengage the retainers (1) at the rear column. 3. Remove the weatherstrip from the roof. Installation Procedure 1. Position the roof weatherstrip by the roof. 2. Install the push-in retainers (1) until fully seated. 3. Press the remainder of the weatherstrip onto the roof flange. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair Sunroof / Moonroof Wiring Harness: Service and Repair SUNROOF WIRING HARNESS REPLACEMENT REMOVAL PROCEDURE 1. Remove the headlining trim finish panel. 2. Disconnect the electrical connector from the following components: 2.1. The sunroof control switch (3) 2.2. The sunroof express module (2) 2.3. The sunroof motor (4) 2.4. The body harness (1). 3. Remove the wiring harness from the sunroof. IMPORTANT: - Note the location of the wiring harness. - Note the location of the tie-straps that secure the harness to the drive cables and to the sunroof module. INSTALLATION PROCEDURE 1. Install the wiring harness to the sunroof. 2. Connect the electrical connector to the following components: 2.1. The body harness (1) 2.2. The sunroof control switch (3) 2.3. The sunroof express module (2) 2.4. The sunroof motor (4) 3. Install the headlining trim finish panel. 4. Inspect the sunroof for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures Head Rest: Procedures Head Restraint Replacement - Front Seat HEAD RESTRAINT REPLACEMENT - FRONT SEAT TOOLS REQUIRED J 42214 Headrest Removal Tool REMOVAL PROCEDURE IMPORTANT: The head restraint cover and foam are not serviceable and must be replaced as a unit. 1. Raise the head restraint. 2. Move the seat back cover to gain access to the head restraint guide tubes. 3. Perform the following steps from the back side of the seat back: 3.1. Apply upward tension to the head restraint. 3.2. Position the tip of the J 42214 (1) down along the right rear side of the head restraint guide tube (3) and the release retaining clip (2). 3.3. Push the J 42214 (1) toward the right side of the seat in order to release the retaining clip (2) from notch in the head restraint post. 3.4. Continue to apply upward tension to the head restraint in order to prevent the clip (2) from re-engaging. 3.5. Repeat the performed steps above to the other head restraint guide tube (3). 4. Remove the head restraint from the seat back. INSTALLATION PROCEDURE 1. Position the seat cover to gain access to the head restraint guide tubes. 2. Perform the following procedure in order to install the head restraint (1). 2.1. Insert the posts into the head restraint guide tubes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 7878 2.2. Push the head restraint to the lowest position. 3. Pull up on the head restraint in order to verify that the lock springs are engaged. IMPORTANT: Perform the following step to prevents the head restraint from being removed inadvertently. Head Restraint Guide Replacement HEAD RESTRAINT GUIDE REPLACEMENT REMOVAL PROCEDURE 1. Remove the seat back cover and pad. 2. Squeeze the bottom of the head restraint guide together. Push the guide upwards through the seat back frame. 3. Remove the guide from the seat back frame. INSTALLATION PROCEDURE 1. Install the guide through the opening in the seat back frame. Press inward on the guide until fully seated into the seat back frame. 2. Install the seat back cover and pad. 3. Check the head restraint for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 7879 Head Rest: Removal and Replacement Head Restraint Guide Replacement Head Restraint Guide Replacement Removal Procedure 1. Remove the seat back cover and pad. 2. Squeeze the bottom of the head restraint guide together. Push the guide upwards through the seat back frame. 3. Remove the guide from the seat back frame. Installation Procedure 1. Install the guide through the opening in the seat back frame. Press inward on the guide until fully seated into the seat back frame. 2. Install the seat back cover and pad. 3. Check the head restraint for proper operation. Front Seat Head Restraint Replacement Front Seat Head Restraint Replacement Tools Required J 42214 Headrest Removal Tool Removal Procedure Important: The head restraint cover and foam are not serviceable and must be replaced as a unit. 1. Raise the head restraint. 2. Move the seat back cover to gain access to the head restraint guide tubes. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 7880 3. Perform the following steps from the back side of the seat back: 1. Apply upward tension to the head restraint. 2. Position the tip of the J 42214 (1) down along the right rear side of the head restraint guide tube (3) and the release retaining clip (2). 3. Push the J 42214 (1) toward the right side of the seat in order to release the retaining clip (2) from notch in the head restraint post. 4. Continue to apply upward tension to the head restraint in order to prevent the clip (2) from re-engaging. 5. Repeat the performed steps above to the other head restraint guide tube (3). 4. Remove the head restraint from the seat back. Installation Procedure 1. Position the seat cover to gain access to the head restraint guide tubes. 2. Perform the following procedure in order to install the head restraint (1). 1. Insert the posts into the head restraint guide tubes. 2. Push the head restraint to the lowest position. Important: Perform the following step to prevents the head restraint from being removed inadvertently. 3. Pull up on the head restraint in order to verify that the lock springs are engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 7889 Memory Positioning Systems: Description and Operation Vehicle Personalization PERSONALIZATION CHIME LEVEL ADJUSTMENT - RDS RADIOS ONLY In order to adjust the chime level, perform the following steps: 1. Turn the ignition ON. 2. Turn the radio OFF. 3. Press and hold the radio push-button 6 until either LOUD or NORMAL appears on the radio display. The chime sounds 3 times for each volume change. 4. To toggle the setting, press and hold the radio push-button 6 again. PROGRAMMING FEATURES WITH TECH 2 Enter Programming To enter Programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select F0: Body Control Module 5. Select F2: Special Functions 6. Select F2: Personalization Setting Options Select an option with the UP/DOWN ARROW keys. The selected option will be highlighted. Use the SIDE-TO-SIDE ARROW keys to activate or deactivate the highlighted options, an ASTERISK will be displayed when an option has been ACTIVATED. Use the SOFT keys to save the selected options or use the EXIT key to leave the options unchanged. After all options have been selected press the SOFT key to continue. The following is a list of the selectable options: 1. Remote Function Activation (RFA) Audible Unlock Feedback 2. RFA Audible Lock Feedback 3. RFA Visual Feedback 4. Pre-Alarm Horn Chirp Additional Information Refer to Audible Warnings Description and Operation in Instrument Panel, Gages, and Console for more information about the chime. Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about RFA. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Driver Personalization > Page 7890 Memory Positioning Systems: Description and Operation Personalization Description and Operation PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DIC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. For more information on driver personalization features for this vehicle, refer to Driver Personalization. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Without RPO Code AJ7 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front Without RPO Code AJ7 SEAT BACK FRAME REPLACEMENT - FRONT WITHOUT RPO CODE AJ7 REMOVAL PROCEDURE 1. Remove the front bucket seat. 2. Remove the seat back cover and pad. 3. Remove the head restraint guides (4 ) from the seat back frame (11). 4. Remove the recliner bolts (6) from the seat back frame (11). 5. Remove the pivot bolt (10) from the seat back frame (11) 6. Remove the seat back frame (11) from the recliner (8). INSTALLATION PROCEDURE 1. Install the seat back frame (11) to the recliner (8). 2. Install the recliner bolts (6). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the pivot bolt (10). Tighten Tighten the bolts to 20 N.m (15 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Without RPO Code AJ7 > Page 7896 4. Install the head restraint guides (4 ) to the seat back frame (11). 5. Install the seat back cover and pad. 6. Install the front bucket seat. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Without RPO Code AJ7 > Page 7897 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front With RPO Code AJ7 SEAT BACK FRAME REPLACEMENT - FRONT WITH RPO CODE AJ7 REMOVAL PROCEDURE 1. Disable the SIR system. 2. Remove the front bucket seat. 3. Remove the seat back cover and pad. 4. Remove the head restraint guides (6) from the seat back frame (7). 5. Unfasten the wire harness for the inflatable restraint module. 6. Remove the recliner bolts (9). 7. Remove the pivot bolt (13). 8. Remove the seat back frame (7) from the recliner (11). INSTALLATION PROCEDURE 1. Install the seat back frame (7) to the recliner (11). 2. Install the recliner bolts (9). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 20 N.m (15 lb ft). 3. Install the pivot bolt (13). Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Without RPO Code AJ7 > Page 7898 Tighten the bolts to 20 N.m (15 lb ft). 4. Fasten the wire harness for the inflatable restraint module. 5. Install the head restraint guides (6) from the seat back frame (7). 6. Install the seat back cover and pad. 7. Install the front bucket seat. 8. Enable the SIR system. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7903 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7904 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7905 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7906 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 7907 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Back Cushion Cover Replacement (With AJ7) Seat Cover: Service and Repair Front Seat Back Cushion Cover Replacement (With AJ7) Front Seat Back Cushion Cover Replacement (With AJ7) Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system. Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. 2. Remove the head restraint from the seat back. 3. Remove the seat back from the seat cushion frame. 4. Remove the Side Impact Air Bag (SIAB) module. 5. If equipped, remove the recliner release lever knob (8) from the recliner (11). 6. Unfasten the J-hook retainer (1) located on the bottom of the seat back. 7. Pull the bottom of the seat back cover assembly (2) up and over the frame (7). Installation Procedure 1. Pull the bottom of the seat back cover assembly (2) down and over the frame (7). 2. Fasten the J-hook retainer (1) located on the bottom of the seat back. 3. If equipped, install the recliner release lever knob (8) to the recliner (11). 4. Install the Side Impact Air Bag (SIAB) module. 5. Install the seat back to the seat cushion frame. 6. Install the head restraint to the seat back. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Back Cushion Cover Replacement (With AJ7) > Page 7910 7. Enable the SIR system. Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Back Cushion Cover Replacement (With AJ7) > Page 7911 Seat Cover: Service and Repair Front Seat Back Cushion Cover Replacement (Without AJ7) Front Seat Back Cushion Cover Replacement (Without AJ7) Removal Procedure 1. Remove the front bucket seat back. 2. Remove the front seat head restraint. 3. Disconnect the J-hook retainer (1). 4. Remove the release lever knob (5) from the recliner (8), if equipped. 5. Pull the bottom of the seat back cover assembly (2) up and over the frame (11). Installation Procedure 1. Pull the bottom of the seat back cover assembly (2) down and over the frame (11). 2. Connect the J-hook retainer (1). 3. Install the release lever knob (5) to the recliner (8), if equipped. 4. Install the head restraint. 5. Install the front bucket seat back. 6. Reposition the front seat back to the original position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Front Seat Back Cushion Cover Replacement (With AJ7) > Page 7912 Seat Cover: Service and Repair Front Seat Cushion Cover Replacement Front Seat Cushion Cover Replacement Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system, if equipped with Side Impact Air Bag (SIAB). Refer to SIR Disabling and Enabling, or SIR Disabling and Enabling in Restraint Systems. 2. Remove the front bucket seat. 3. Remove the front seat back from the seat cushion. 4. Disconnect the front bucket seat cover J-hook retainers (2) from the front seat cushion frame (3). 5. Remove the front seat cover and pad (1) from the seat frame (3). Installation Procedure 1. Position the front seat pad and cover (1) to the front seat cushion frame (3). 2. Connect the front seat pad and cover J-hook retainers (2) to the front seat cushion frame (3). 3. Install the front bucket seat back to the front seat cushion. 4. Install the front bucket seat. 5. Enable the SIR system, if equipped with SIAB. Refer to SIR Disabling and Enabling, or SIR Disabling and Enabling in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures Seat Cushion: Procedures Seat Cushion Cover Replacement - Front SEAT CUSHION COVER REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Disable the SIR system, if equipped with Side Impact Air Bag (SIAB). CAUTION: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 2. Remove the front bucket seat. 3. Remove the front seat back from the seat cushion. 4. Disconnect the front bucket seat cover J-hook retainers (2) from the front seat cushion frame (3). 5. Remove the front seat cover and pad (1) from the seat frame (3). INSTALLATION PROCEDURE 1. Position the front seat pad and cover (1) to the front seat cushion frame (3). 2. Connect the front seat pad and cover J-hook retainers (2) to the front seat cushion frame (3). 3. Install the front bucket seat back to the front seat cushion. 4. Install the front bucket seat. 5. Enable the SIR system, if equipped with SIAB. Seat Cushion Replacement - Front SEAT CUSHION REPLACEMENT - FRONT Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7917 REMOVAL PROCEDURE 1. Disable the SIR system, if equipped with side impact inflatable restraints. CAUTION: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 2. Remove the front bucket seat. 3. Remove the seat cushion outer trim panel screws. 4. Remove the seat cushion outer trim panel from the recliner. 5. With a flat-bladed tool remove the lumbar knob from the actuator, if equipped. 6. Remove the lumbar actuator from the cushion frame, if equipped. 7. Unfasten the lumbar actuator cable from the cushion frame, if equipped. 8. Unfasten the wire harness for the Side Impact Air Bag (SIAB) from the cushion frame, if equipped. 9. Remove the seat back recliner bolts (6). 10. Remove the seat back pivot bolt (3). 11. Remove the seat back (1) from the seat cushion (5). INSTALLATION PROCEDURE 1. Install the seat back (1) to the seat cushion (5). 2. Install the seat back pivot bolt (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 20 N.m (15 lb ft). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7918 3. Install the seat recliner bolts (6). Tighten Tighten the bolts to 20 N.m (15 lb ft). 4. Fasten the wire harness for the SIAB to the cushion frame, if equipped. 5. Fasten the lumbar actuator cable to the cushion frame, if equipped. 6. Install the lumbar actuator to the cushion frame, if equipped. 7. Align the lumbar knob to the splines on the actuator, if equipped. Press onto the actuator until fully engaged. 8. Install the seat cushion outer trim panel to the recliner. 9. Install the seat cushion outer trim panel screws. Tighten Tighten the screws to 1.9 N.m (17 lb in). 10. Install the bucket seat. 11. Enable the SIR system, if equipped with side impact inflatable restraints. Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Disable the SIR system, if equipped with Side Impact Air Bag (SIAB). CAUTION: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling Zones. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 2. Remove the seat cushion from the seat back. 3. Remove the seat adjusters from the seat frame. 4. On the driver side, remove the seat belt buckle bolt. Remove the seat belt buckle (6) from the cushion frame (1). 5. Unfasten the J-hook retainers (3) from the seat cushion frame (1). 6. Remove the seat cushion cover (2) from the seat cushion frame (1). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7919 1. Install the seat cushion cover (2) to the seat cushion frame (1). 2. Fasten the J-hook retainers (3) to the seat cushion frame (1). 3. On the driver side install the seat belt buckle (6) to the cushion frame (1). 4. Install the seat belt buckle bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 20 N.m (15 lb ft). 5. Install the seat adjusters to the seat frame. 6. Install the seat cushion to the seat back. 7. Enable the SIR system, if equipped with SIAB. Seat Cushion Outer Trim Panel Replacement SEAT CUSHION OUTER TRIM PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the screws from the front bucket seat cushion outer trim panel. 2. Remove the front seat cushion outer trim panel from the front seat recliner mechanism. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7920 1. Install the seat bucket cushion outer trim panel to the front seat recliner mechanism. 2. Install the screws to the front bucket seat cushion outer trim panel. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.9 N.m (17 lb in). Seat Cushion Replacement - Rear SEAT CUSHION REPLACEMENT - REAR REMOVAL PROCEDURE 1. Use a flat-bladed tool (1) in order to press the lower rear seat cushion retainer rearward. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7921 2. Remove the rear seat cushion (1) lifting upward and out. INSTALLATION PROCEDURE 1. Align the lower rear seat cushion (1) over the retainer brackets (2). 2. Install the rear seat cushion pressing downward and rearward on the lower rear seat cushion (1) in order to latch the retainer (3) to the retainer bracket. 3. Inspect the rear seat cushion for proper installation by pulling up on the rear seat cushion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7922 Seat Cushion: Removal and Replacement Front Seat Cushion Frame Replacement Front Seat Cushion Frame Replacement Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. 1. Disable the SIR system, if equipped with Side Impact Air Bag (SIAB). Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. 2. Remove the seat cushion from the seat back. 3. Remove the seat adjusters from the seat frame. 4. On the driver side, remove the seat belt buckle bolt. Remove the seat belt buckle (6) from the cushion frame (1). 5. Unfasten the J-hook retainers (3) from the seat cushion frame (1). 6. Remove the seat cushion cover (2) from the seat cushion frame (1). Installation Procedure 1. Install the seat cushion cover (2) to the seat cushion frame (1). 2. Fasten the J-hook retainers (3) to the seat cushion frame (1). 3. On the driver side install the seat belt buckle (6) to the cushion frame (1). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7923 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the seat belt buckle bolt. Tighten the bolt to 34 N.m (25 lb ft). 5. Install the seat adjusters to the seat frame. 6. Install the seat cushion to the seat back. 7. Enable the SIR system, if equipped with SIAB. Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Removal Procedure 1. Remove the screws from the front bucket seat cushion outer trim panel. 2. Remove the front seat cushion outer trim panel from the front seat recliner mechanism. Installation Procedure 1. Install the seat bucket cushion outer trim panel to the front seat recliner mechanism. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the front bucket seat cushion outer trim panel. Tighten the screws to 1.9 N.m (17 lb in). Front Seat Cushion Replacement Front Seat Cushion Replacement Removal Procedure Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Refer to SIR Disabling and Enabling. Failure to observe the correct procedure could cause deployment of the SIR components, personal injury, or unnecessary SIR system repairs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7924 1. Disable the SIR system, if equipped with side impact inflatable restraints. Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. 2. Remove the front bucket seat. 3. Remove the seat cushion outer trim panel screws. 4. Remove the seat cushion outer trim panel from the recliner. 5. With a flat-bladed tool remove the lumbar knob from the actuator, if equipped. 6. Remove the lumbar actuator from the cushion frame, if equipped. 7. Unfasten the lumbar actuator cable from the cushion frame, if equipped. 8. Unfasten the wire harness for the Side Impact Air Bag (SIAB) from the cushion frame, if equipped. 9. Remove the seat back recliner bolts (6). 10. Remove the seat back pivot bolt (3). 11. Remove the seat back (1) from the seat cushion (5). Installation Procedure 1. Install the seat back (1) to the seat cushion (5). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the seat back pivot bolt (3). Tighten the bolt to 20 N.m (15 lb ft). 3. Install the seat recliner bolts (6). Tighten the bolts to 20 N.m (15 lb ft). 4. Fasten the wire harness for the SIAB to the cushion frame, if equipped. 5. Fasten the lumbar actuator cable to the cushion frame, if equipped. 6. Install the lumbar actuator to the cushion frame, if equipped. 7. Align the lumbar knob to the splines on the actuator, if equipped. Press onto the actuator until fully engaged. 8. Install the seat cushion outer trim panel to the recliner. 9. Install the seat cushion outer trim panel screws. Tighten the screws to 1.9 N.m (17 lb in). 10. Install the bucket seat. 11. Enable the SIR system, if equipped with side impact inflatable restraints. Refer to SIR Disabling and Enabling or SIR Disabling and Enabling in Restraint Systems. Rear Seat Cushion Replacement Rear Seat Cushion Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 7925 1. Use a flat-bladed tool (1) in order to press the lower rear seat cushion retainer rearward. 2. Remove the rear seat cushion (1) lifting upward and out. Installation Procedure 1. Align the lower rear seat cushion (1) over the retainer brackets (2). 2. Install the rear seat cushion pressing downward and rearward on the lower rear seat cushion (1) in order to latch the retainer (3) to the retainer bracket. 3. Inspect the rear seat cushion for proper installation by pulling up on the rear seat cushion. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair Seat Latch: Service and Repair Rear Folding Seat Back Latch Striker Replacement Removal Procedure 1. Remove the seat back. 2. Adjust the seat back cover and the pad in order to access the latch striker. Refer to Rear Split Folding Seat Back Cushion Cover and Pad Replacement. 3. Drill out the rivet (2) for the latch striker (3). 4. Remove the latch striker (3) from the seat back frame (1). Installation Procedure 1. Install the latch striker (3) to the seat back frame (1). 2. Install the rivets (2) to the latch striker (3). Use a rivet gun to attach the latch striker (3) to the seat back frame (1). 3. Adjust the seat back cover and the pad to the desired appearance. Refer to Rear Split Folding Seat Back Cushion Cover and Pad Replacement. 4. Install the rear seat back. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Door Lock Switch - Driver With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7933 Door Lock Switch - Front Passenger With RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7934 Door Lock Switch - Driver Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 7935 Door Lock Switch - Front Passenger Without RPO Code AUO Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures Power Door Lock Switch: Procedures POWER DOOR LOCK SWITCH REPLACEMENT REMOVAL PROCEDURE 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. INSTALLATION PROCEDURE 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Procedures > Page 7938 Power Door Lock Switch: Removal and Replacement Door Lock Switch Replacement Removal Procedure 1. If the power door lock switch is located in the door trim panel release the retaining tabs using a flat-bladed tool. Remove the switch from the door trim panel. 2. If the power door lock switch is located in the door handle bezel remove the bezel from the door trim panel. 3. Disconnect the electrical connector (2) from the power door lock switch (1). 4. With the flat-bladed tool release the retaining tabs for the door lock switch on the trim bezel. 5. Remove the power door lock switch (1) from the trim bezel. Installation Procedure 1. Install the power door lock switch (1) to the trim bezel. Press the switch into the trim bezel until retainers are fully engaged. 2. Connect the electrical connector (2) to the power door lock switch (1). 3. If the power door lock switch is located in the door handle bezel install the bezel to the door trim panel. 4. If the power door lock switch is located in the door trim panel install the switch into the trim panel. Press the switch into the door trim panel until retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Driver Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7942 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 7943 Outside Rearview Mirror Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). INSTALLATION PROCEDURE 1. Install the switch (2) to the trim panel (1). 2. Begin tightening the set screw (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 7946 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement Removal Procedure 1. Remove the door trim panel. 2. Disconnect the electrical connector for the power mirror switch (2). 3. Loosen the set screw (3) enough to remove the switch (2). 4. Remove the switch (2) from the upper extension trim panel (1). Installation Procedure 1. Install the switch (2) to the trim panel (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Begin tightening the set screw (3). Tighten the set screw to 1.4 N.m (12 lb in). 3. Connect the electrical connector to the switch (2). 4. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Limit Switch > Component Information > Description and Operation Sunroof / Moonroof Limit Switch: Description and Operation SUNROOF LIMIT SWITCHES The sunroof limit switches track the position of the sunroof glass through two limit switches: - Soft Stop limit switch through the sunroof limit switch soft stop signal circuit - Vent Stop limit switch through the sunroof limit switch range signal circuit The sunroof control module monitors the limit switches and based on the input combinations, determines the position of the sunroof glass. As a sunroof limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module monitors both sunroof switch input requests and based on the sunroof limit switch input combinations, will control an output to the sunroof motor, to drive the sunroof glass to the requested position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Dome Lamp And Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 7953 Sunroof Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures Sunroof / Moonroof Switch: Procedures SUNROOF SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Procedures > Page 7956 Sunroof / Moonroof Switch: Removal and Replacement Sunroof Switch Replacement Removal Procedure 1. Use a small, flat-bladed tool in order to disengage the sunroof control switch from the headlining module. 2. Disconnect the connector from the sunroof control switch. 3. Remove the sunroof control switch from the vehicle. Installation Procedure 1. Connect the connector to the sunroof control switch. 2. Firmly push the sunroof control switch into the headlining module in order to secure the sunroof control switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7960 Rear Compartment Lid Release Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 7961 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool to release the retaining tabs for the rear compartment lid switch. Remove the switch from the Instrument Panel (IP) carrier. 2. Disconnect the electrical connector. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Install the switch to the IP carrier. Press the switch until the retaining tabs are fully engaged. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair Air Dam: Service and Repair Hood Close Out Filler Replacement Removal Procedure 1. Raise and support the hood. 2. Remove the push-pin retainers. 3. Remove the hood close out panel. Installation Procedure 1. Install the hood close out panel. 2. Install the hood close out panel push-in retainers. 3. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures Spoiler: Procedures SPOILER REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the nut from the rear compartment lid spoiler. 2. Remove the bolts from the spoiler. 3. Disconnect the wire harness connector (1) from the spoiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures > Page 7970 4. Use both hands to remove the spoiler by lifting the center of the spoiler. If necessary, pull on the outboard edges of the spoiler to unseat the spoiler grommets. INSTALLATION PROCEDURE 1. Position the spoiler on the rear compartment lid. 2. Push firmly on the outboard edges of the spoiler to seat the spoiler into the grommets on the rear compartment lid. 3. Pull gently on the wire harness of the spoiler in order to seat the grommet. 4. Connect the wire harness connector (1) to the spoiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures > Page 7971 5. Install the spoiler nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 5 N.m (44 lb in). 6. Install the spoiler bolts (4). Tighten Tighten the bolts to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures > Page 7972 Spoiler: Removal and Replacement Rear Spoiler Replacement (Chevrolet) Removal Procedure 1. Remove the nut from the rear compartment lid spoiler. 2. Remove the bolts from the spoiler. 3. Disconnect the wire harness connector (1) from the spoiler. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures > Page 7973 4. Use both hands to remove the spoiler by lifting the center of the spoiler. If necessary, pull on the outboard edges of the spoiler to unseat the spoiler grommets. Installation Procedure 1. Position the spoiler on the rear compartment lid. 2. Push firmly on the outboard edges of the spoiler to seat the spoiler into the grommets on the rear compartment lid. 3. Pull gently on the wire harness of the spoiler in order to seat the grommet. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Procedures > Page 7974 4. Connect the wire harness connector (1) to the spoiler. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the spoiler nut. Tighten the nut to 5 N.m (44 lb in). 6. Install the spoiler bolts (4). Tighten the bolts to 5 N.m (44 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Service and Repair Strut / Shock Tower: Service and Repair FRONT SUSPENSION SUPPORT BRACE REPLACEMENT REMOVAL PROCEDURE 1. Raise the vehicle on a hoist. Refer to Vehicle Lifting. 2. Remove the bolt (2) from the front suspension support brace (3) and the front suspension crossmember (1). 3. Remove the bolt (4) from the front suspension support brace (3) and the lower tie bar (5). 4. Remove the front suspension support brace (3) from the vehicle. INSTALLATION PROCEDURE 1. Install the front suspension support brace (3) to the vehicle. 2. Install the bolt (4) to the suspension support brace (3) and lower the tie bar (5). Hand tighten the bolt. 3. Install the bolt (4) to the front suspension support brace (3) and the front suspension crossmember (1). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the bolts to 72 N.m (53 lb ft). 4. Lower the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778 Door Trim Pad and Garnish Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arm assemblies. 3. Disconnect the washer tubing from the air inlet screen. 4. Using J 38778, remove the air inlet grille panel push-in retainers (1) from the panel. 5. Remove the air inlet grille panel from the vehicle. Installation Procedure 1. Position the air inlet grille panel to the vehicle. 2. Install the air inlet grille panel push-in retainers (1) to the panel. 3. Connect the washer tubing to the air inlet panel. 4. Install the wiper arms and blade assemblies. 5. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Auxiliary Sealing Strip Replacement Front Side Door Auxiliary Sealing Strip Replacement Removal Procedure 1. Pull the roof weatherstrip back from the front auxiliary weatherstrip. 2. Remove the bolts (3) from the auxiliary weatherstrip. 3. Using a flat-bladed tool, remove the push-in retainer (2). 4. Remove the auxiliary weatherstrip (1) from the front column. Installation Procedure 1. Position the auxiliary weatherstrip (1) on the front column. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front auxiliary weatherstrip bolts (3). Tighten the front auxiliary weatherstrip bolts to 2 N.m (18 lb in). 3. Install the push-in retainer (2) pressing in until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement > Page 7988 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Coupe) Front Door Opening Weatherstrip Replacement (Coupe) Removal Procedure 1. Remove the carpet retainer from the vehicle. 2. Remove the windshield garnish molding. 3. Loosen the quarter trim panel. Refer to Rear Quarter Trim Panel Replacement in Interior Trim. 4. Pull the front door opening weatherstrip (1) loose and remove it from the vehicle. Installation Procedure 1. Apply weather-strip adhesive GM P/N 12345096 (Canadian P/N 993365) or equivalent, to the front door opening weatherstrip (1). 2. Install the front door opening weather-strip (1) onto the front door pinch weld, pressing into place until fully seated. 3. Install the windshield garnish molding. 4. Install the quarter trim panel. 5. Install the carpet retainer to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Auxiliary Sealing Strip Replacement > Page 7989 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Sedan) Front Door Opening Weatherstrip Replacement (Sedan) Removal Procedure 1. Remove the carpet retainer from the vehicle. 2. Remove the windshield garnish molding. 3. Remove the center pillar trim. 4. Pull the front door opening weatherstrip (1) loose and remove it from the vehicle. Installation Procedure 1. Apply weatherstrip adhesive GM P/N 12345096, or equivalent, to the front door opening weatherstrip (1). 2. Install the front door opening weatherstrip (1) onto the front door pinch weld, pressing into place until fully seated. 3. Install the windshield garnish molding. 4. Install the center pillar trim. 5. Install the carpet retainer to the vehicle. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Door Window Channel Replacement Door Window Channel Replacement Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door rear view mirror. 5. Remove the sealing strip, window belt outer. 6. Remove the channel (2) lower bolt (3). 7. Remove the push-in retainer (1) at the top of the channel. 8. Remove the window run channel weather-strip from the front door window (4). Installation Procedure 1. Install the run channel weather-strip (2) to the front door window. 2. Install the push-in retainer (1) at the top of the channel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the channel lower bolt (3). Tighten the upper window channel lower bolt to 6 N.m (53 lb in). 4. Install the sealing strip, window belt outer. 5. Install the front door rear view mirror. 6. Install the front door window. 7. Install the front door water deflector. 8. Install the front door trim panel. Front Side Door Window Rear Channel Replacement Front Side Door Window Rear Channel Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 7994 Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door reveal molding by the window rear channel. 5. Remove the bolt from the rear channel (2). 6. Lift up the rear channel to disengage the top clip. 7. Remove the window rear channel (1) from the front door. Installation Procedure 1. Position the rear run channel (1) in the front door. 2. Lift up the rear channel to install the top clip. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the window rear channel bolt (2). Tighten the lower window channel bolt 6 N.m (53 lb in). 4. Install the reveal molding. 5. Install the front door window. 6. Install the front door water deflector. 7. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 7995 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (1) from the door sealing strip. 3. Remove the door sealing strip (2). Installation Procedure 1. Install the door sealing strip (2). 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (1) to the door sealing strip. Tighten the door sealing strip screw (1) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Plenum to Hood Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Pull the hood rear seal (1) from the pinch weld. Installation Procedure 1. Position the hood rear seal to the vehicle. 2. Push the hood rear seal (1) into the pinch weld in order to fully seat the seal. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Plenum to Hood > Page 8000 Hood Weatherstrip: Service and Repair Hood Rear Outer Seal Replacement Hood Rear Outer Seal Replacement Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal, located at the end of the plenum to hood seal, from the fender. 3. Remove the seal from the vehicle. 4. Clean any adhesive from the pinch-weld flange and hood hinge using 3M(TM) P/N 8984. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. With the rear side hood seal butted to the plenum to hood seal, press the side hood seal until the adhesive is fully adhered. 3. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Removal Procedure 1. Remove the carpet retainer. 2. Remove the upper center pillar trim panel from the vehicle. 3. Remove the rear lower quarter trim panel. 4. Remove the rear upper quarter trim panel. 5. Pull the rear door opening weatherstrip (2) loose. 6. Remove the weatherstrip (2) from the vehicle. Installation Procedure 1. Apply weatherstrip (2) adhesive GM P/N 12345096 (Canadian P/N 993365) or equivalent, to the rear door opening weatherstrip. 2. Press the rear door opening weather-strip (2) onto the rear door opening flange. 3. Install the carpet retainer. 4. Install the upper center pillar trim panel in the vehicle. 5. Install the rear lower quarter trim panel. 6. Install the rear upper quarter trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 8005 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement Rear Side Door Front Auxiliary Weatherstrip Replacement Removal Procedure 1. Use a flat-bladed tool in order to disengage the push-pin retainers (1). 2. Remove the center column auxiliary weatherstrip from the vehicle. Installation Procedure 1. Position the auxiliary weatherstrip on the center column. 2. Firmly press in the push-in retainers (1) making sure they are all seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement > Page 8006 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Rear Side Door Bottom Auxiliary Sealing Strip Replacement Removal Procedure 1. Remove the screws (2) from the rear door lower sealing strip. 2. Remove the rear door lower sealing strip (1) from the quarter panel. Installation Procedure 1. Position the rear door lower sealing strip (1) on the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws (2) to the rear door lower sealing strip. Tighten the door sealing strip screws to 2 N.m (13 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Front Channel Replacement Removal Procedure 1. Ensure that the window is fully closed. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the window regulator. 5. Lower the window to the bottom of the door. 6. Remove the lower bolt (2). 7. Lift the channel to disconnect the upper fastener. 8. Remove the front window channel (1) from the door. Installation Procedure 1. Position the front window channel (1) in the door, top end first. 2. Insert the channel top retainer into the slot. 3. Rotate the top of the front window channel rearward and align it on the lower edge of the window. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear door window channel lower bolt (2). Tighten the lower window channel bolt to 6 N.m (53 lb in). 5. Lift up the window and install the window regulator. 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 8011 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Side Door Window Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (3) from the door sealing strip. 3. Lift up to remove the door sealing strip (2) from the door. Installation Procedure 1. Position the door sealing strip (2) to the door. 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (3) to the door sealing strip. Tighten the door sealing strip screw (3) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures Sunroof / Moonroof Weatherstrip: Procedures SUNROOF SEAL/MOLDING REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof window. 2. Remove the weatherstrip by pulling the weatherstrip (1) away from the glass panel. INSTALLATION PROCEDURE 1. Align the butt joint with the center of the sunroof window on the passenger side of the vehicle. 2. Work the weatherstrip into the channel in the glass panel frame. Continue to work the weatherstrip (1) until the weatherstrip is firmly press fit into the channel. Install the weatherstrip around the entire sunroof glass panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 8016 3. Install the sunroof window. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 8017 Sunroof / Moonroof Weatherstrip: Removal and Replacement Sunroof Seal/Molding Replacement Sunroof Seal/Molding Replacement Removal Procedure 1. Remove the sunroof window. 2. Remove the weatherstrip by pulling the weatherstrip (1) away from the glass panel. Installation Procedure 1. Align the butt joint with the center of the sunroof window on the passenger side of the vehicle. 2. Work the weatherstrip into the channel in the glass panel frame. Continue to work the weatherstrip (1) until the weatherstrip is firmly press fit into the channel. Install the weatherstrip around the entire sunroof glass panel. 3. Install the sunroof window. Roof Side Rail Weatherstrip Replacement Roof Side Rail Weatherstrip Replacement Removal Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Procedures > Page 8018 1. Pull off the roof auxiliary weatherstrip (2) from the roof flange beginning from the front pillar weatherstrip. 2. Use a flat-bladed took to disengage the retainers (1) at the rear column. 3. Remove the weatherstrip from the roof. Installation Procedure 1. Position the roof weatherstrip by the roof. 2. Install the push-in retainers (1) until fully seated. 3. Press the remainder of the weatherstrip onto the roof flange. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Removal Procedure 1. Peel the weatherstrip from the pinch weld flange. Move the weatherstrip in the following direction: 1. Toward the lower corners 2. Around the complete opening 2. Clean all of the adhesive from the pinch-weld flange. Installation Procedure 1. Apply a bead of weatherstrip adhesive GM P/N 12345096 to the following areas: 1. The edge of the pinch-weld flange 2. Around the entire perimeter of the rear compartment opening 2. Install the center of the weatherstrip onto the gutter flange. Begin at the forward center of the opening between the hinge arms. 3. Push down by hand on the weatherstrip over the entire area until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8026 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments CLUTCH RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard. The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 4.1. The release switch (1) 4.2. The stoplamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 8030 Clutch Switch: Service and Repair CLUTCH RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. 4. Install the left instrument panel insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8034 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8035 Cruise Control Module (CCM) Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8036 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT (2.2L L61) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector (1) from the cruise control module. 3. Open the throttle body cam slightly. 4. Disconnect the cruise control cable from the throttle body cam lever. 5. Remove the cruise control cable from the throttle body bracket. 6. Remove the cruise control cable from the retainer clip on the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8037 7. Disconnect the cruise control cable from the cruise control module by turning the cable 1/4 turn counterclockwise. 8. Disconnect the cruise control cable slug from the ribbon buckle. 9. Remove the bolts (1) from the cruise control module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8038 10. Remove the bolt and nut (1) from the cruise control module mounting bracket. 11. Remove the cruise control module from the engine compartment. INSTALLATION PROCEDURE 1. Position the cruise control module to the mounting bracket. 2. Install the bolts (1) to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to the cruise control module to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8039 3. Position the cruise control module to the engine compartment. 4. Install the bolt and nut (1) to the cruise control module mounting bracket. Tighten Tighten the nuts to the cruise control module to 10 N.m (89 lb in). 5. Connect the cruise control cable slug to the ribbon buckle. IMPORTANT: The ribbon must not be twisted. 6. Insert the cruise control cable into the cruise control module until the seal touches the module. 7. Position the narrow cable tab into the narrow slot and the wide tab into the wide slot. 8. Connect the cruise control cable to the cruise control module by turning the cable clockwise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 8040 IMPORTANT: The adjuster tab must be pointing toward the front of the car after installation. 9. Connect the electrical connector to the cruise control module. 10. Install the cruise control cable to the throttle body bracket pressing into place until fully seated. 11. Open the throttle body cam slightly. 12. Connect the cruise control cable to the throttle body cam lever. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control ON/OFF Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Powertrain Control Module (PCM) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8048 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8049 Cruise Control Module (CCM) Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8050 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT (2.2L L61) REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector (1) from the cruise control module. 3. Open the throttle body cam slightly. 4. Disconnect the cruise control cable from the throttle body cam lever. 5. Remove the cruise control cable from the throttle body bracket. 6. Remove the cruise control cable from the retainer clip on the engine. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8051 7. Disconnect the cruise control cable from the cruise control module by turning the cable 1/4 turn counterclockwise. 8. Disconnect the cruise control cable slug from the ribbon buckle. 9. Remove the bolts (1) from the cruise control module. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8052 10. Remove the bolt and nut (1) from the cruise control module mounting bracket. 11. Remove the cruise control module from the engine compartment. INSTALLATION PROCEDURE 1. Position the cruise control module to the mounting bracket. 2. Install the bolts (1) to the cruise control module. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to the cruise control module to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8053 3. Position the cruise control module to the engine compartment. 4. Install the bolt and nut (1) to the cruise control module mounting bracket. Tighten Tighten the nuts to the cruise control module to 10 N.m (89 lb in). 5. Connect the cruise control cable slug to the ribbon buckle. IMPORTANT: The ribbon must not be twisted. 6. Insert the cruise control cable into the cruise control module until the seal touches the module. 7. Position the narrow cable tab into the narrow slot and the wide tab into the wide slot. 8. Connect the cruise control cable to the cruise control module by turning the cable clockwise. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 8054 IMPORTANT: The adjuster tab must be pointing toward the front of the car after installation. 9. Connect the electrical connector to the cruise control module. 10. Install the cruise control cable to the throttle body bracket pressing into place until fully seated. 11. Open the throttle body cam slightly. 12. Connect the cruise control cable to the throttle body cam lever. 13. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 8059 Cruise Control Brake Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments Clutch Switch: Adjustments CLUTCH RELEASE SWITCH ADJUSTMENT 1. Ensure that the cruise control release switch is fully seated in the bracket. 2. Slowly pull the brake pedal rearward until the audible clicking is no longer heard. The switch will be moved in the retainer providing adjustment. 3. Release the brake pedal. 4. Ensure that the following contacts open at 25.4 mm (1 in) or less of pedal travel: 4.1. The release switch (1) 4.2. The stoplamp and torque converter clutch (TCC) switch. 5. Ensure the switches open simultaneously or before the onset of braking. 6. The brake pedal may travel up to 25.4 mm (1 in) before the cruise control system disengages. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Adjustments > Page 8063 Clutch Switch: Service and Repair CLUTCH RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the electrical connector from the cruise control release switch. 3. Remove the cruise control release switch from the bracket. INSTALLATION PROCEDURE 1. Depress the brake pedal and insert the cruise control release switch into the bracket until the retainer is fully seated. 2. Connect the electrical connector to the cruise control release switch. 3. Adjust the cruise control release switch as needed. 4. Install the left instrument panel insulator. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control ON/OFF Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams Audible Warning Device: Diagrams Audible Warnings Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 8071 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the audible warnings through the left front speaker. The radio receives audible warning requests via the class 2 serial data line. If the radio receives multiple audible warning requests, the warning with the highest priority sounds first. The following lists the audible warning priority and the pulse rate: 1. Fast rate chime-200 pulses per minute 2. Medium rate chime-150 pulses per minute 3. Slow rate chime-50 pulses per minute 4. Single chime No chime will sound when a loss of class 2 communications with the BCM and or radio occurs. Fasten Safety Belt Warning The radio activates the fasten safety belt audible warning as requested by the BCM. The BCM sends a class 2 message to the radio indicating the chime frequency of a slow rate and an 8 second duration. The fasten safety belt warning sounds and the fasten safety belt indicator illuminates when the following occurs: The ignition switch transitions to ON. - The inflatable restraint sensing and diagnostic module (SDM) detects that the driver's seat belt is not buckled and or the signal is low. The SDM sends a class 2 message to the body control module (BCM) indicating the seat belt status. The IPC receives a class 2 message from the BCM indicating the driver's seat belt status. If the seat belt is buckled when the ignition is turned ON, the chime does not sound. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to ON, the chime does not sound. Key in Ignition Warning The radio activates the key-in-ignition audible warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a medium rate and a continuous duration. The key-in-ignition warning sounds when the following occurs: The ignition switch is OFF. - The body control module (BCM) determines that the driver's door is open and the signal circuit is low. - The BCM determines that the key-in-ignition switch is closed and the signal circuit is low. Lights On Warning The radio activates the lights on warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a fast rate and a continuous duration. The lights on warning sounds when the following occurs: The ignition is OFF. - The BCM determines that the driver's door is open and the signal circuit is low. - The BCM determines that the headlamp switch is in the park or head position. Overspeed Warning (Export) The radio activates the overspeed warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a medium rate and a continuous duration. The overspeed warning sounds when the BCM senses that the vehicle speed is above 120 km/h via a class 2 message from the powertrain control module (PCM). The overspeed warning turns off when the BCM senses that the vehicle speed is below 110 km/h. Park Brake Warning The radio activates the park brake audible warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a fast rate and a continuous duration. The park brake warning sounds and the BRAKE indicator illuminates when the following occurs: The ignition is ON. - The vehicle speed is greater than 5 km/h (3.1 mph). The BCM receives a class 2 message from the PCM indicating the vehicle speed. - The BCM determines that the park brake is engaged and the signal circuit is low. Reverse Warning The radio activates the reverse audible warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the medium rate chime frequency and a continuous duration. The reverse warning sounds when the following occurs: The ignition is ON with the engine ON. - The vehicle is in reverse for at least one second. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams Brake Warning System Diagrams Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Connector Views Cigar Lighter Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Connector Views > Page 8079 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 8080 Cigarette Lighter: Service and Repair CIGAR LIGHTER HOUSING REPLACEMENT - INSTRUMENT PANEL (I/P) TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the cigarette lighter fuse. IMPORTANT: The Chevrolet is shown, the Pontiac is similar. 2. Remove the cigarette lighter element. 3. Position the steering wheel one half turn to the right for access to the lighter. 4. Remove the cigarette lighter socket by placing one side of the T portion of J 42059 into the tab window and then the other should be angled into the opposite tab window, then pull the lighter socket straight out. 5. Remove the tool from the lighter socket. 6. Disconnect the electrical connector from the cigarette lighter socket. 7. Remove the cigarette lighter retainer using your index finger and pulling out. INSTALLATION PROCEDURE 1. Position the cigarette lighter retainer with the key to the slot into the cigarette lighter hole. 2. Install the cigarette lighter retainer pressing into place until fully seated. 3. Connect the electrical connector to cigarette lighter socket. 4. Align the cigarette lighter socket to the cigarette lighter retainer and press into place until fully seated. 5. Reposition the steering wheel. 6. Install the cigarette lighter fuse. 7. Install the cigarette lighter element. 8. Inspect the instrument panel lighter for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8086 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8087 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8088 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8089 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8090 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8091 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8092 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8093 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8094 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8095 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8096 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8097 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8098 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8099 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8100 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8101 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8102 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8103 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8104 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8105 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8106 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8107 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8108 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8109 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8110 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8111 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams I/P Dimmer Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams > Page 8115 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the dimmer lamp switch using a small flat-bladed tool. 5. Remove the dimmer lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the dimmer lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the to the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8120 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8121 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8124 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8125 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8126 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8127 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Page 8128 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8131 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8132 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8133 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation FUEL GAUGE The PCM sends fuel level percent to the BCM via class 2. The IPC displays the fuel level as determined by the BCM. The IPC receives a class 2 message from the BCM indicating the fuel level percent. The fuel gage defaults to E (empty) if: - The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the BCM. - The BCM detects a loss of class 2 communications with the PCM. When the fuel level is less than 4%, the CHECK GAGES indicator illuminates. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 8144 Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 8145 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 8146 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 8147 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Enabling And Disabling Zones Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8153 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8154 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the hood closeout filler panel. Refer to Hood Close Out Filler Replacement in Body Front End. 7. Remove the connector position assurance (CPA) from the inflatable restraint electronic front end sensor (EFS) connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8155 8. Disconnect the EFS connector from the EFS. Zone 2 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8156 6. Remove the LH door trim panel (2). 7. Remove the inflatable restraint side impact sensor (SIS)-LH (1) from the LH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 2 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8157 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the LH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-LH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-LH connector (4). 9. Disconnect the SIS-LH connector (4). Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8158 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the Connector Position Assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Driver Shorting Bar Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8159 7. Disconnect the inflatable restraint steering wheel module coil connector. Zone 5 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. Passenger Shorting Bar 6. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8160 7. Disconnect the inflatable restraint IP module inline connector. Zone 6 (Coupe) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8161 7. Remove the inflatable restraint side impact sensor (SIS)-RH (1) from the RH door (4). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 6 (Sedan) 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8162 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the RH center pillar upper trim. 7. Remove the inflatable restraint side impact sensor (SIS)-RH from the center pillar (1). 8. Remove the connector position assurance (CPA) (3) from the SIS-RH connector (4). 9. Disconnect the SIS-RH connector (4). Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8163 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - LF connector located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8164 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn the ignition switch to the OFF position. 3. Remove the key from the ignition switch. 4. Remove the LH IP outer trim cover. 5. Remove the AIR BAG Fuse from the LH IP wiring harness junction block. IMPORTANT: With the AIR BAG Fuse removed and the ignition switch in the RUN position, the AIR BAG warning lamp illuminates. This is a normal operation and does not indicate an SIR system malfunction. 6. To disable the inflatable restraint side impact module, skip to Step 13. To disable the entire SIR system, continue to Step 7. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8165 Driver Shorting Bar 8. Disconnect the inflatable restraint steering wheel module coil connector. Passenger Shorting Bar 9. Remove the CPA from the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. 10. Disconnect the inflatable restraint IP module inline connector. 11. Remove the CPA from the inflatable restraint side impact module - LF connector located under the driver seat. 12. Disconnect the side impact module - LF connector. 13. Remove the connector position assurance (CPA) from the inflatable restraint side impact module - RF connector located under the passenger seat. 14. Disconnect the side impact module - RF connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8166 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition switch. 2. Connect the EFS connector to the EFS. 3. Install the CPA to the EFS connector. 4. Install the hood closeout filler panel. 5. Install the AIR BAG Fuse to the LH IP wiring harness junction block. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8167 6. Install the LH IP outer trim cover. 7. Staying well away from both air bags, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH (1) to the LH door (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8168 5. Install the LH door trim panel (2). 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8169 1. Remove the key from the ignition switch. 2. Connect the SIS-LH connector (4). 3. Install the CPA (3) to the SIS-LH connector (4). 4. Install the SIS-LH to the center pillar (1). 5. Install the LH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8170 Driver Shorting Bar 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint steering wheel module coil connector. 3. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8171 Zone 5 1. Remove the key from the ignition switch. 2. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 3. Install the connector position assurance (CPA) to the inflatable restraint IP module inline connector. 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8172 Zone 6 (Coupe) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). 4. Install the SIS-RH (1) to the RH door (4). 5. Install the RH door trim panel (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8173 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 6 (Sedan) 1. Remove the key from the ignition switch. 2. Connect the SIS-RH connector (4). 3. Install the CPA (3) to the SIS-RH connector (4). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8174 4. Install the SIS-RH to the center pillar (1). 5. Install the RH center pillar upper trim. 6. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 7. Install the LH IP outer trim cover. 8. Staying well away from both air bags, turn ON the ignition. 8.1. The AIR BAG indicator will flash 7 times. 8.2. The AIR BAG indicator will then turn OFF. 9. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8175 1. Remove the key from the ignition switch. 2. Connect the side impact module - LF connector located under the driver seat. 3. Install the CPA to the inflatable restraint side impact module - LF connector (1). 4. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 5. Install the LH IP outer trim cover. 6. Staying well away from both air bags, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 1. Remove the key from the ignition switch. 2. To enable the inflatable restraint side impact module, skip to Step 9. To enable the entire SIR system, continue to Step 3. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8176 3. Connect the inflatable restraint IP module inline connector located under the instrument panel, left of the steering column. Passenger Shorting Bar 4. Install the CPA to the inflatable restraint IP module inline connector. Driver Shorting Bar 5. Connect the inflatable restraint steering wheel module coil connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8177 6. Install the CPA to the inflatable restraint steering wheel module coil connector, located under the instrument panel, left of the steering column. 7. Connect the side impact module - LF connector located under the driver seat. 8. Install the CPA to the inflatable restraint side impact module - LF connector. 9. Connect the side impact module RF connector located under the passenger seat. 10. Install the CPA to the inflatable restraint side impact module - RF connector. 11. Install the AIR BAG Fuse to the LH IP wiring harness junction block. 12. Install the LH IP outer trim cover. 13. Staying well away from both air bags, turn ON the ignition. 13.1. The AIR BAG indicator will flash 7 times. 13.2. The AIR BAG indicator will then turn OFF. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 8178 14. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair INSTRUMENT PANEL CLUSTER (IPC) INDICATOR LAMP REPLACEMENT The IP cluster contains no serviceable bulbs. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned "ON", with the engine "OFF". This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns "OFF" after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns "OFF" after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is "ON". * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled "OFF" and then "ON". SERVICE VEHICLE SOON The instrument panel cluster (IPC) illuminates the service vehicle soon indicator during any of the following conditions: * The body control module (BCM) detects a PASSLOCK failure. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a malfunction in the passive trunk release system. The BCM sends a class 2 message to the IPC requesting illumination. * The BCM detects a failure in the traction control system. The BCM sends a class 2 message to the IPC requesting illumination. * The IPC detects a mismatch between its part number and the vehicle platform configuration sent by the BCM via a class 2 message. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 8188 Malfunction Indicator Lamp: Service and Repair CHECK ENGINE OR SERVICE ENGINE SOON The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either "SERVICE ENGINE SOON" or one of the following symbols when commanded ON: RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8193 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8194 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 8195 Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 8196 Odometer: Description and Operation ODOMETER The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and trip mileage as determined by the BCM. The BCM calculates the mileage based on the vehicle speed signal circuit from the PCM. The odometer will display 'error' if an internal IPC memory failure is detected or there is a loss of class 2 communication. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 8201 Oil Change Reminder Lamp: Service and Repair This vehicle does not use the GM Oil Life System, and does not have an oil life indicator to reset. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 10 Nm (89 inch lbs.) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8205 Oil Pressure Sender: Locations Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8206 Crankshaft Position Sensor,Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8207 Engine Oil Pressure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8208 Crankshaft Position Sensor, Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8209 Engine Oil Pressure Sensor Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 8210 Oil Pressure Sender: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the engine oil pressure sensor electrical connector. 4. Remove the engine oil pressure sensor. Installation Procedure 1. Install the engine oil pressure sensor. 2. Connect the engine oil pressure sensor electrical connector. 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams I/P Dimmer Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Page 8218 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the dimmer lamp switch using a small flat-bladed tool. 5. Remove the dimmer lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the dimmer lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the to the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8223 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8224 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8227 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8228 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8229 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8230 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 8231 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8234 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8235 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8236 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 8240 Fuel Pump And Sender Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 8241 Fuel Gauge Sender: Description and Operation Fuel Level Sensor The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the position of the float arm. The control module sends the fuel level information via the Class 2 circuit to the instrument panel cluster (IPC). This information is used for the IPC fuel gage and the low fuel warning indicator, if applicable. The control module also monitors the fuel level input for various diagnostics. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 8242 Fuel Gauge Sender: Service and Repair REMOVAL PROCEDURE 1. Remove the fuel sender assembly. 2. Remove the fuel pump and fuel level sensor electrical retaining clip at the top of the fuel sender assembly. 3. Disconnect the fuel pump and fuel level sensor electrical connector. 4. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2). 5. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing. 6. Remove the retaining clip from the electrical connector. 7. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 8243 1. Install the fuel level sensor (1) by sliding the sensor down in the housing. IMPORTANT: Make sure the wires are routed under the fuel level sensor. - Make sure the tab locks in place. 2. Slide the upper reservoir into the lower reservoir (2). 3. Connect the 2 wires into the connector and lock the connector with the retaining clip. 4. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip. 5. Install the fuel sender assembly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the console 2. Disconnect the electrical connector (1) from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch mounting screw. 4. Remove the switch. Installation Procedure 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the park brake warning lamp switch mounting screw. ^ Tighten the screw to 3 Nm (27 inch lbs.). 3. Connect the electrical connector (1) to the switch. 4. Install the console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Diagrams Shift Indicator Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Diagrams > Page 8250 Shift Indicator: Description and Operation SHIFT INDICATOR The IPC illuminates the shift indicator when the PCM determines that the vehicle should be shifted to the next higher gear. The IPC receives a class 2 message from the PCM requesting illumination. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed based on the information from the BCM. The BCM receives a class 2 message from the PCM indicating the vehicle speed. The PCM calculates the vehicle speed based on the class 2 message indicating the wheel reference speed from the EBCM if: - The PCM detects a malfunction in the vehicle speed sensor circuit. - The IPC detects a loss of class 2 communications with the BCM. The speedometer defaults to 0 km/h (0 mph) if the BCM detects a loss of class 2 communications with both the PCM and the EBCM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed as determined by the BCM via a class 2 message. The BCM receives a class 2 message from the PCM indicating the engine speed. The tachometer will default to 0 RPM if: - The PCM detects a malfunction in the engine speed sensor circuit. - The IPC detects a loss of class 2 communications with the BCM. - The BCM detects a loss of class 2 communications with the PCM. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 8270 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Page 8275 Transmission Shift Position Indicator Lamp: Service and Repair TRANS FLOOR SHIFT CONTROL INDICATOR LAMP REPLACEMENT REMOVAL PROCEDURE 1. Remove the front floor console. 2. Disconnect the shift control bulb/socket from the shift control. 3. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Connect the shift control bulb/socket to the shift control. 3. Install the front floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8281 Backup Lamp Switch (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8282 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Disconnect the backup lamp connector. 2. Remove the backup light switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Page 8283 1. Install the backup light switch using pipe sealant GM P/N 1052080 or equivalent. Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8288 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views Brake Lamp: Connector Views Stop/Turn Lamp - Left Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views > Page 8291 Stop/Turn Lamp - Right Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Page 8292 Brake Lamp: Description and Operation STOP LAMPS The STOP/HAZ fuse in the IP fuse block supplies battery positive voltage to the normally open stop lamp switch. When the driver presses the brake pedal, the switch contacts close and battery positive voltage is supplied to both left and right stop lamp assemblies and the center high mounted stop lamp (CHMSL). The stop lamps are grounded at G302 and G304. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8296 Brake Light Switch: Diagrams Stop Lamp Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8297 Stop Lamp Switch C2 (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8298 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT The stop lamp switch is self adjusting when properly installed. The switch does not need any further adjustment. Refer to Stop Lamp Switch Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8299 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the lower I/P trim insulator screw. 2. Remove the lower I/P trim insulator from the brake pedal bracket. 3. Disconnect the electrical connections (3, 4) from the stop lamp switch (5). 4. Rotate the stop lamp switch (5) counterclockwise until the travel stop has been reached. 5. Pull the stop lamp switch (5) rearward. 6. Remove the stop lamp switch (5) from the brake pedal bracket (1). INSTALLATION PROCEDURE 1. Install the stop lamp switch (3) into the retainer (2). IMPORTANT: The brake pedal must be attached to the power booster rod and undisturbed during the switch install. Do not press the brake pedal during the installation of the switch. 2. Push the stop lamp switch (3) into the retainer (2) until the switch plunger is fully depressed into the switch barrel. IMPORTANT: Approximately 2-3 lb of force is required to depress the switch plunger flush with the switch barrel. Too much force could flex the brake pedal bracket and result in the stop lamp switch not being properly adjusted. 3. Rotate the stop lamp switch (3) clockwise until the travel stop has been reached. 4. With a feeler gage check to ensure the minimum plunger extension is not less than 0.0 mm (0.0 in), and not greater than 2.0 mm (0.78 in) between the stop lamp switch barrel (3) and the brake pedal (4). 5. Connect the electrical connectors to the stop lamp switch. 6. Install the lower I/P trim insulator to the brake pedal bracket. 7. Install the lower I/P trim insulator screw. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8300 Tighten Tighten the screw to 2.3 N.m (20 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair Cargo Lamp: Service and Repair CARGO LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lamp from the rear shelf using a small flat-bladed tool to release the retainers. 3. Disconnect the electrical connector (3) from rear compartment lamp (2). 4. Remove the bulb from the rear compartment lamp. INSTALLATION PROCEDURE 1. Install the bulb to the rear compartment lamp (1). 2. Connect the electrical connector (3) to the rear compartment lamp. 3. Install the rear compartment lamp to the rear shelf pressing into place until fully seated. 4. Close the rear compartment. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Diagrams Center High Mounted Stop Lamp (CHMSL) Bulbs Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair Cornering Lamp: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (CHEVROLET) REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 1. Open the hood. 2. Remove the hood close out filler panel. 3. Remove the bolts from the headlamp assembly. 4. Position the headlamp assembly away from the vehicle to access the bulb electrical connectors. 5. Remove the sidemarker lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 8311 6. Remove the turn signal lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. 7. Disconnect the electrical connector from the headlamp, if necessary. 8. Remove the headlamp assembly from the vehicle, if necessary. 9. Remove the bulb access cover from behind the headlamp bulb, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 8312 10. Disconnect the electrical connector from the headlamp bulb/socket, if necessary. 11. Remove the headlamp bulb/socket retainer ring from the headlamp by turning the ring counterclockwise, if necessary. 12. Remove the headlamp bulb/socket from the headlamp assembly by pulling the socket straight out, if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 8313 1. Install the headlamp bulb/socket to the headlamp assembly until the socket is fully seated. 2. Install the headlamp bulb/socket retainer ring to the headlamp by rotating the socket clockwise until locked. 3. Connect the electrical connector to the headlamp bulb/socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 8314 4. Install the bulb access cover behind the headlamp bulb by turning the cover clockwise until tight. 5. Position the headlamp assembly to the vehicle 6. Connect the electrical connector to the headlamp assembly. 7. Install the turn signal lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 8315 8. Install the sidemarker lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. 9. Position the headlamp assembly to the body and to the lower mounting bracket. 10. Install the bolts to the headlamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the headlamp bolts to 4.5 N.m (40 lb in). 11. Install the hood close out filler panel. 12. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Connector Views Courtesy Lamp: Connector Views Reading/Courtesy Lamp Switch - Left Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Connector Views > Page 8320 Reading/Courtesy Lamp Switch - Right Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Page 8321 Courtesy Lamp: Description and Operation COURTESY/ILLUMINATED ENTRY LAMPS These lamps may be manually turned on by placing the interior lamp switch in the ON position, or by opening a door. - The Roof Rail/Reading Lamps - The Footwell Lamps - The Dome Lamp - The Rear View Mirror Lamps The RDO/INT LP fuse in the IP fuse block, supplies battery positive voltage to the body control module (BCM). The inadvertent power control circuit of the BCM then supplies battery positive voltage to the dome lamp, the left and right courtesy lamps, the reading lamps, and the rear compartment lamp. When any door is opened, the door jamb switch contacts close providing a door open input to the BCM. The BCM then provides a ground to the interior lamps. The dome lamp assembly may contain two map lamps, each map lamp may be turned ON or OFF using its own switch. The rear view mirror may contain two reading lamps, each reading lamp may be manually turned ON or OFF using its own switch. The map and reading lamps are grounded at G204. If the driver inadvertently leaves any interior lamp on the BCM will turn it off after a 20 minute time-out. The courtesy lamps will normally turn off using the theater dimming feature. The BCM provides a pulse width modulated ground to left and right hand courtesy/reading lamps and the dome lamp for the theater dimming feature. The courtesy lamps will also turn off immediately if a door lock command is received with all the doors closed, or if the ignition switch is turned to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Resistor > Component Information > Service and Repair Daytime Running Lamp Resistor: Service and Repair DAYTIME RUNNING LAMPS (DRL) RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the right headlamp assembly. 3. Disconnect the daytime running lamp (DRL) resistor electrical connector. 4. Remove the DRL resistor bolt. 5. Remove the DRL resistor from the frame rail. INSTALLATION PROCEDURE 1. Position the DRL resistor to the right frame rail. 2. Install the DRL resistor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 7 N.m (62 lb in). 3. Connect the DRL resistor electrical connector. 4. Install the right headlamp assembly. 5. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams I/P Dimmer Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams > Page 8329 Dimmer Switch: Service and Repair INSTRUMENT PANEL (I/P) DIMMER SWITCH REPLACEMENT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the dimmer lamp switch using a small flat-bladed tool. 5. Remove the dimmer lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the dimmer lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the to the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair Dome Lamp Bulb: Service and Repair DOME LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. From the rear of the dome lamp lens, insert a flat-bladed tool (1) between the dome lamp lens and the headliner (2). 2. Use the flat bladed tool in order to push the tab at the rear of the dome lamp lens forward. Disengage the tab from the headliner. 3. Pull the dome lamp lens rearward in order to disengage the 2 tabs at the front of the dome lamp lens. 4. Remove the dome lamp bulb from the socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Page 8334 5. Remove the reading lamp bulb from the socket, if equipped. INSTALLATION PROCEDURE 1. Install the reading lamp bulb to the socket, if equipped. 2. Install the bulb to the socket. 3. Insert the 2 forward tabs on the dome lamp lens into the appropriate holes in the headliner (2). 4. Push at the rear of the dome lamp lens until the rear tab is fully seated in the headliner. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8339 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8340 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8343 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8344 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8345 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8346 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 8347 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8350 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8351 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8352 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Headlamp, Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 8357 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8361 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the fog lamp switch using a small flat-bladed tool. 5. Remove the fog lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the fog lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams Turn Signal/Hazard Flasher Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Page 8366 Hazard Warning Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the hazard and turn signal flasher module (1) from the brake pedal bracket (3). 2. Disconnect the electrical connector (2) from the flasher module (1). 3. Remove the flasher module (1) from the vehicle , if required. INSTALLATION PROCEDURE 1. Connect the electrical connector (2) to the flasher module (1). 2. Install the flasher module (1) to the brake pedal bracket (3). 3. Press the flasher module (1) until the rosebud retainer is secured to the brake pedal bracket (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (CHEVROLET) REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 1. Open the hood. 2. Remove the hood close out filler panel. 3. Remove the bolts from the headlamp assembly. 4. Position the headlamp assembly away from the vehicle to access the bulb electrical connectors. 5. Remove the sidemarker lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8374 6. Remove the turn signal lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. 7. Disconnect the electrical connector from the headlamp, if necessary. 8. Remove the headlamp assembly from the vehicle, if necessary. 9. Remove the bulb access cover from behind the headlamp bulb, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8375 10. Disconnect the electrical connector from the headlamp bulb/socket, if necessary. 11. Remove the headlamp bulb/socket retainer ring from the headlamp by turning the ring counterclockwise, if necessary. 12. Remove the headlamp bulb/socket from the headlamp assembly by pulling the socket straight out, if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8376 1. Install the headlamp bulb/socket to the headlamp assembly until the socket is fully seated. 2. Install the headlamp bulb/socket retainer ring to the headlamp by rotating the socket clockwise until locked. 3. Connect the electrical connector to the headlamp bulb/socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8377 4. Install the bulb access cover behind the headlamp bulb by turning the cover clockwise until tight. 5. Position the headlamp assembly to the vehicle 6. Connect the electrical connector to the headlamp assembly. 7. Install the turn signal lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 8378 8. Install the sidemarker lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. 9. Position the headlamp assembly to the body and to the lower mounting bracket. 10. Install the bolts to the headlamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the headlamp bolts to 4.5 N.m (40 lb in). 11. Install the hood close out filler panel. 12. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8387 Horn Relay Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Lamp (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 8392 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT (SEDAN AND COUPE) REMOVAL PROCEDURE 1. Remove the license plate from the rear bumper fascia. 2. Remove the screws from the license plate lamp. 3. Remove the license plate lamp (1) from the rear bumper fascia. 4. Remove the bulb/socket from the license plate lamp (1) by turning counterclockwise. 5. Remove the bulb from the of socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Install the socket to the license plate lamp by turning the socket clockwise. 3. Install the license plate lamp (1) to the rear bumper fascia. 4. Install the screws (3) to the license plate lamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the license plate lamp screws to 2 N.m (18 lb in). 5. Install the license plate to the rear bumper fascia. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations Headliner Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Reading/Courtesy Lamp Switch Map Light: Diagrams Reading/Courtesy Lamp Switch Reading/Courtesy Lamp Switch - Left Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Reading/Courtesy Lamp Switch > Page 8398 Reading/Courtesy Lamp Switch - Right Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Reading/Courtesy Lamp Switch > Page 8399 Rear View Mirror Reading Lamps Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Reading/Courtesy Lamp Switch > Page 8400 Map Light: Diagrams Reading Lamp Reading Lamp - Left Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Reading/Courtesy Lamp Switch > Page 8401 Reading Lamp - Right Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views Marker Lamp: Connector Views Marker Lamp - LF Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Connector Views > Page 8406 Marker Lamp - RF Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 8407 Marker Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned ON when the headlamp switch is placed in the PARK or HEADLAMP position. The EXT LAMP fuse in the IP fuse block supplies battery positive voltage to the headlamp switch. When the headlamp switch is placed in the PARK or HEADLAMP position, current flows through the headlamp switch to the park, tail and marker lamps and then to ground at G102, G302, and G304. If the park lamps are turned ON , they will remain ON until turned OFF or the battery runs dead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn Marker Lamp: Service and Repair Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (CHEVROLET) REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 1. Open the hood. 2. Remove the hood close out filler panel. 3. Remove the bolts from the headlamp assembly. 4. Position the headlamp assembly away from the vehicle to access the bulb electrical connectors. 5. Remove the sidemarker lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8410 6. Remove the turn signal lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. 7. Disconnect the electrical connector from the headlamp, if necessary. 8. Remove the headlamp assembly from the vehicle, if necessary. 9. Remove the bulb access cover from behind the headlamp bulb, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8411 10. Disconnect the electrical connector from the headlamp bulb/socket, if necessary. 11. Remove the headlamp bulb/socket retainer ring from the headlamp by turning the ring counterclockwise, if necessary. 12. Remove the headlamp bulb/socket from the headlamp assembly by pulling the socket straight out, if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8412 1. Install the headlamp bulb/socket to the headlamp assembly until the socket is fully seated. 2. Install the headlamp bulb/socket retainer ring to the headlamp by rotating the socket clockwise until locked. 3. Connect the electrical connector to the headlamp bulb/socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8413 4. Install the bulb access cover behind the headlamp bulb by turning the cover clockwise until tight. 5. Position the headlamp assembly to the vehicle 6. Connect the electrical connector to the headlamp assembly. 7. Install the turn signal lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8414 8. Install the sidemarker lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. 9. Position the headlamp assembly to the body and to the lower mounting bracket. 10. Install the bolts to the headlamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the headlamp bolts to 4.5 N.m (40 lb in). 11. Install the hood close out filler panel. 12. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Service and Repair > Hdlp ASSY or Hdlp Bulb and/or Cornering, Sidemarker, Park, Turn > Page 8415 Marker Lamp: Service and Repair Marker Lamp Replacement - Side MARKER LAMP REPLACEMENT - SIDE REMOVAL PROCEDURE 1. Remove the screw (3) from the side marker lamp (2). 2. Remove the side marker lamp (2) from the front and/or rear bumper fascia. 3. Remove the bulb/socket from the side marker lamp. 4. Remove the bulb from the socket, INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Install the bulb/socket to the side marker lamp (2). 3. Install the side marker lamp (2) to the front and/or rear bumper fascia. 4. Install the screw (3) to the side marker lamp (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the side marker lamp screw to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Parking Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8420 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views Parking Lamp: Connector Views Park/Turn Signal Lamp - LF Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Connector Views > Page 8423 Park/Turn Signal Lamp - RF Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8424 Parking Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned ON when the headlamp switch is placed in the PARK or HEADLAMP position. The EXT LAMP fuse in the IP fuse block supplies battery positive voltage to the headlamp switch. When the headlamp switch is placed in the PARK or HEADLAMP position, current flows through the headlamp switch to the park, tail and marker lamps and then to ground at G102, G302, and G304. If the park lamps are turned ON , they will remain ON until turned OFF or the battery runs dead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8425 Parking Lamp: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (CHEVROLET) REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 1. Open the hood. 2. Remove the hood close out filler panel. 3. Remove the bolts from the headlamp assembly. 4. Position the headlamp assembly away from the vehicle to access the bulb electrical connectors. 5. Remove the sidemarker lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8426 6. Remove the turn signal lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. 7. Disconnect the electrical connector from the headlamp, if necessary. 8. Remove the headlamp assembly from the vehicle, if necessary. 9. Remove the bulb access cover from behind the headlamp bulb, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8427 10. Disconnect the electrical connector from the headlamp bulb/socket, if necessary. 11. Remove the headlamp bulb/socket retainer ring from the headlamp by turning the ring counterclockwise, if necessary. 12. Remove the headlamp bulb/socket from the headlamp assembly by pulling the socket straight out, if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8428 1. Install the headlamp bulb/socket to the headlamp assembly until the socket is fully seated. 2. Install the headlamp bulb/socket retainer ring to the headlamp by rotating the socket clockwise until locked. 3. Connect the electrical connector to the headlamp bulb/socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8429 4. Install the bulb access cover behind the headlamp bulb by turning the cover clockwise until tight. 5. Position the headlamp assembly to the vehicle 6. Connect the electrical connector to the headlamp assembly. 7. Install the turn signal lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Page 8430 8. Install the sidemarker lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. 9. Position the headlamp assembly to the body and to the lower mounting bracket. 10. Install the bolts to the headlamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the headlamp bolts to 4.5 N.m (40 lb in). 11. Install the hood close out filler panel. 12. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Headlamp, Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 8435 Fog Lamp Relay Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Behind Left Side Of The Instrument Panel Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8439 Horn Relay Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Top Of Transmission (MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8444 Backup Lamp Switch (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8445 Backup Lamp Switch: Service and Repair Backup Lamp Switch Replacement Removal Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. 1. Disconnect the backup lamp connector. 2. Remove the backup light switch assembly. Installation Procedure Notice: When removing or installing the backup lamp switch, do not use an open end wrench. Use only a socket in order to avoid damage to the switch assembly. Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Page 8446 1. Install the backup light switch using pipe sealant GM P/N 1052080 or equivalent. Tighten the switch to 33 Nm (24 ft. lbs.). 2. Connect the backup lamp connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Below The Left Side Of The IP, Near The Steering Column Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8450 Brake Light Switch: Diagrams Stop Lamp Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8451 Stop Lamp Switch C2 (With RPO Code MM5) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8452 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT The stop lamp switch is self adjusting when properly installed. The switch does not need any further adjustment. Refer to Stop Lamp Switch Replacement. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8453 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the lower I/P trim insulator screw. 2. Remove the lower I/P trim insulator from the brake pedal bracket. 3. Disconnect the electrical connections (3, 4) from the stop lamp switch (5). 4. Rotate the stop lamp switch (5) counterclockwise until the travel stop has been reached. 5. Pull the stop lamp switch (5) rearward. 6. Remove the stop lamp switch (5) from the brake pedal bracket (1). INSTALLATION PROCEDURE 1. Install the stop lamp switch (3) into the retainer (2). IMPORTANT: The brake pedal must be attached to the power booster rod and undisturbed during the switch install. Do not press the brake pedal during the installation of the switch. 2. Push the stop lamp switch (3) into the retainer (2) until the switch plunger is fully depressed into the switch barrel. IMPORTANT: Approximately 2-3 lb of force is required to depress the switch plunger flush with the switch barrel. Too much force could flex the brake pedal bracket and result in the stop lamp switch not being properly adjusted. 3. Rotate the stop lamp switch (3) clockwise until the travel stop has been reached. 4. With a feeler gage check to ensure the minimum plunger extension is not less than 0.0 mm (0.0 in), and not greater than 2.0 mm (0.78 in) between the stop lamp switch barrel (3) and the brake pedal (4). 5. Connect the electrical connectors to the stop lamp switch. 6. Install the lower I/P trim insulator to the brake pedal bracket. 7. Install the lower I/P trim insulator screw. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8454 Tighten Tighten the screw to 2.3 N.m (20 lb in) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8458 Combination Switch: Service and Repair MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Service Precautions/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). 4. Install the steering column trim covers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8459 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver Driver Door - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8464 Passenger Door Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Door Jamb Switch - Driver > Page 8465 Under Driver Side Carpet Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver Door Jamb Switch - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8468 Door Switch: Diagrams Door Jamb Switch - Front Passenger Door Jamb Switch - Front Passenger (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8469 Door Jamb Switch - Front Passenger (Sedan) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8470 Door Jamb Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Door Jamb Switch - Driver > Page 8471 Door Jamb Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 8472 Door Switch: Description and Operation DOOR AJAR SWITCHES The CTD system uses the door ajar switches in the door jambs as one method to activate the alarm. The body control module (BCM) monitors all door ajar switches via a discrete input from each door ajar switch, including the rear compartment. If the BCM receives a ground signal from a door ajar switch when the CTD system is armed, the BCM activates the alarm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front Door Switch: Service and Repair Door Jamb Switch Replacement - Front DOOR JAMB SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the door jamb. 2. Disconnect the door jamb switch electrical connector. 3. Remove the door jamb switch from the vehicle door pillar. INSTALLATION PROCEDURE IMPORTANT: When a new jamb switch is installed and the door is closed the first time, the plunger is forced into the sleeve and automatically adjusts the jamb switch for that particular door. If a jamb switch fails, do not readjust the switch. Install a new jamb switch. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8475 1. Position the door jamb switch by the pillar. 2. Connect the door jamb switch electrical connector. 3. Install the door jamb switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the door jamb switch to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8476 Door Switch: Service and Repair Door Jamb Switch Replacement - Rear DOOR JAMB SWITCH REPLACEMENT - REAR REMOVAL PROCEDURE 1. Open the rear door. 2. Use a small flat-bladed tool remove the door jamb switch (2) from the hinge pillar. 3. Disconnect the electrical connector from the door jamb switch. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Service and Repair > Door Jamb Switch Replacement - Front > Page 8477 1. Connect the electrical connector to the door jamb switch. 2. Press inward on the door jamb switch (2) until fully seated in the hinge pillar. 3. Close the rear door. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 8481 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE Location View 1. Remove the instrument panel accessory trim plate to access the fog lamp switch. 2. Release the retainers on the fog lamp/dimmer switch housing using a small flat-bladed tool. 3. Remove the fog lamp/dimmer switch (3) housing from the instrument panel accessory trim plate. 4. Release the retainers on the fog lamp switch using a small flat-bladed tool. 5. Remove the fog lamp switch from the fog lamp/dimmer switch (3) housing. INSTALLATION PROCEDURE Location View 1. Install the fog lamp switch to the fog lamp/dimmer switch housing, pressing into place until fully seated. 2. Install the fog lamp/dimmer switch (3) housing to the instrument panel accessory trim plate, pressing into place until fully seated. 3. Install the instrument panel accessory trim plate. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8488 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 8489 Turn Signal Multifunction Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8492 4. Install the steering column trim covers. 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8493 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Upper Bearing Thrust Washer TURN SIGNAL CANCEL CAM AND UPPER BEARING THRUST WASHER TOOLS REQUIRED - J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/SIR Caution 2. Remove the SIR coil. 3. Remove and discard the bearing retainer using J 23653-SIR and J 42137. 4. Remove the shaft lock (1). 5. Remove the turn signal cancel cam (2). 6. Remove the upper bearing spring (3). 7. Remove the upper bearing inner race (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8494 1. Install the upper bearing inner race (4). 2. Install the upper bearing spring (3). 3. Install the turn signal cancel cam (2). 4. Lubricate the turn signal cancel cam (2) with GM P/N 12377900 (Canadian P/N 10953529). 5. Install the shaft lock (1). 6. Install the bearing retainer using J 23653-SIR and J 42137. 7. Install the SIR coil. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 8499 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 8500 Tail Lamp: Description and Operation PARK, TAIL AND MARKER LAMPS The park, tail and marker lamps, including the license lamps, are turned ON when the headlamp switch is placed in the PARK or HEADLAMP position. The EXT LAMP fuse in the IP fuse block supplies battery positive voltage to the headlamp switch. When the headlamp switch is placed in the PARK or HEADLAMP position, current flows through the headlamp switch to the park, tail and marker lamps and then to ground at G102, G302, and G304. If the park lamps are turned ON , they will remain ON until turned OFF or the battery runs dead. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Page 8501 Tail Lamp: Service and Repair TAIL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Pull back the rear compartment trim to access the tail lamp. 2. Disconnect the electrical connector (1) from the tail lamp. 3. Remove the bulb/socket from the tail lamp. 4. Remove the bulb from the socket, if required. 5. Remove the nuts (2) from the tail lamp. 6. Remove the tail lamp from the quarter panel. INSTALLATION PROCEDURE 1. Install the tail lamp to the quarter panel. NOTE: Refer to Electrical Wiring Routing Notice in Service Precautions. 2. Install the tail lamp nuts (2) to the tail lamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the tail lamp nuts (2) to 5 N.m (44 lb in). 3. Connect the electrical connector (1) to the tail lamp. 4. Install the bulb to the socket, if required. 5. Install the bulb /socket to the tail lamp. 6. Pull back the rear compartment trim. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Diagrams Rear Compartment Lamp Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8509 Combination Switch: Service and Repair MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Service Precautions/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). 4. Install the steering column trim covers. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8510 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Service and Repair Turn Signal Cancel Cam: Service and Repair TURN SIGNAL CANCEL CAM AND UPPER BEARING THRUST WASHER TOOLS REQUIRED - J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Service Precautions/SIR Caution 2. Remove the SIR coil. 3. Remove and discard the bearing retainer using J 23653-SIR and J 42137. 4. Remove the shaft lock (1). 5. Remove the turn signal cancel cam (2). 6. Remove the upper bearing spring (3). 7. Remove the upper bearing inner race (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Service and Repair > Page 8514 1. Install the upper bearing inner race (4). 2. Install the upper bearing spring (3). 3. Install the turn signal cancel cam (2). 4. Lubricate the turn signal cancel cam (2) with GM P/N 12377900 (Canadian P/N 10953529). 5. Install the shaft lock (1). 6. Install the bearing retainer using J 23653-SIR and J 42137. 7. Install the SIR coil. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams Turn Signal/Hazard Flasher Module Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams > Page 8518 Turn Signal Flasher: Service and Repair HAZARD AND TURN SIGNAL FLASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the hazard and turn signal flasher module (1) from the brake pedal bracket (3). 2. Disconnect the electrical connector (2) from the flasher module (1). 3. Remove the flasher module (1) from the vehicle , if required. INSTALLATION PROCEDURE 1. Connect the electrical connector (2) to the flasher module (1). 2. Install the flasher module (1) to the brake pedal bracket (3). 3. Press the flasher module (1) until the rosebud retainer is secured to the brake pedal bracket (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (CHEVROLET) REMOVAL PROCEDURE CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 1. Open the hood. 2. Remove the hood close out filler panel. 3. Remove the bolts from the headlamp assembly. 4. Position the headlamp assembly away from the vehicle to access the bulb electrical connectors. 5. Remove the sidemarker lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8523 6. Remove the turn signal lamp bulb/socket from the headlamp by rotating the bulb/socket counterclockwise, if necessary. 7. Disconnect the electrical connector from the headlamp, if necessary. 8. Remove the headlamp assembly from the vehicle, if necessary. 9. Remove the bulb access cover from behind the headlamp bulb, if necessary. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8524 10. Disconnect the electrical connector from the headlamp bulb/socket, if necessary. 11. Remove the headlamp bulb/socket retainer ring from the headlamp by turning the ring counterclockwise, if necessary. 12. Remove the headlamp bulb/socket from the headlamp assembly by pulling the socket straight out, if necessary. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8525 1. Install the headlamp bulb/socket to the headlamp assembly until the socket is fully seated. 2. Install the headlamp bulb/socket retainer ring to the headlamp by rotating the socket clockwise until locked. 3. Connect the electrical connector to the headlamp bulb/socket. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8526 4. Install the bulb access cover behind the headlamp bulb by turning the cover clockwise until tight. 5. Position the headlamp assembly to the vehicle 6. Connect the electrical connector to the headlamp assembly. 7. Install the turn signal lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 8527 8. Install the sidemarker lamp bulb/socket to the headlamp by rotating the bulb/socket clockwise until fully seated. 9. Position the headlamp assembly to the body and to the lower mounting bracket. 10. Install the bolts to the headlamp. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the headlamp bolts to 4.5 N.m (40 lb in). 11. Install the hood close out filler panel. 12. Close the hood. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8531 Turn Signal Switch: Diagrams Turn Signal Multifunction Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 8532 Turn Signal Multifunction Switch C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement MULTIFUNCTION, TURN SIGNAL SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/Battery Disconnect Caution 2. Remove the steering column trim covers. 3. Remove the retaining screws from the multifunction switch (2). 4. Remove the multifunction switch (2) from the steering column. 5. Disconnect the electrical connectors from the multifunction switch (2). INSTALLATION PROCEDURE 1. Connect the electrical connectors to the multifunction switch (2). 2. Install the multifunction switch (2) to the steering column while depressing the spring loaded horn pin. 3. Install the retaining screws to the multifunction switch (2). NOTE: Refer to Fastener Notice in Service Precautions. See: Steering and Suspension/Service Precautions/Vehicle Damage Warnings/Fastener Notice Tighten Tighten the screws to 4 N.m (36 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8535 4. Install the steering column trim covers. 5. Connect the negative battery cable. 6. Ensure that the multifunction switch functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8536 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Upper Bearing Thrust Washer TURN SIGNAL CANCEL CAM AND UPPER BEARING THRUST WASHER TOOLS REQUIRED - J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming CAUTION: Refer to SIR Caution in Service Precautions. See: Steering and Suspension/Service Precautions/Technician Safety Information/SIR Caution 2. Remove the SIR coil. 3. Remove and discard the bearing retainer using J 23653-SIR and J 42137. 4. Remove the shaft lock (1). 5. Remove the turn signal cancel cam (2). 6. Remove the upper bearing spring (3). 7. Remove the upper bearing inner race (4). INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 8537 1. Install the upper bearing inner race (4). 2. Install the upper bearing spring (3). 3. Install the turn signal cancel cam (2). 4. Lubricate the turn signal cancel cam (2) with GM P/N 12377900 (Canadian P/N 10953529). 5. Install the shaft lock (1). 6. Install the bearing retainer using J 23653-SIR and J 42137. 7. Install the SIR coil. CAUTION: SIR Inflator Module Coil Caution. Improper routing of the wire harness assembly may damage the inflatable restraint steering wheel module coil. This may result in a malfunction of the coil, which may cause personal injury. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8547 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8548 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8549 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8555 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8556 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 8557 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Page 8558 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Page 8559 Rear Of Passenger Compartment Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Connector Views Heated Glass Element: Connector Views Rear Window Defogger Grid C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Connector Views > Page 8562 Rear Window Defogger Grid C2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Connector Views > Page 8563 Heated Glass Element: Electrical Diagrams Defogger Diagram Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 8564 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control assembly - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied through the RR DEFOG fuse in the IP fuse block to the HVAC control assembly. Ignition voltage is supplied through the HVAC fuse in the IP fuse block to the HVAC control assembly. When you turn the ignition to the ON position, and depress the rear window defogger switch. The HVAC control assembly illuminates the rear window defogger indicator and allows battery positive voltage to the rear window defogger. Ground for the rear window defogger is provided by G302. When you start the engine and press the rear window defogger switch for the first time, the defogger cycle lasts for 10 minutes. Further operation results in 5 minute defogger cycles. The defogger cycle resets to 10 minutes when you cycle the ignition to the OFF position and then back to the ON position. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - HEATED GLASS ELEMENT Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8567 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - HEATED GLASS ELEMENT IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the Rear Window Defogger System. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Indicator Always On - Defogger Grid Lines Diagnosis Steps 1-2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8568 Steps 3-7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8569 Steps 1-7 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8570 Steps 8-16 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8571 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. 5. Once the open (2) is located, repair the grid line. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Bus Bar/Antenna Terminal Repair Heated Glass Element: Service and Repair Bus Bar/Antenna Terminal Repair BUS BAR/ANTENNA TERMINAL REPAIR 1. Buff the repair area with fine steel wool. This will remove the oxide coating formed during window manufacturing. 2. Apply paste-type rosin flux in small quantities to the rear defogger bus bar lead wire, antenna or defogger terminal repair area using a brush. 3. Coat the solder iron tip with solder. Use only enough heat to melt the solder and only enough solder to ensure a complete repair. 4. Apply solder to the bus bar. Draw the soldering iron tip across the fluxed area thinly coating bus bar with solder. 5. Apply a small amount of flux to the underside of the rear defogger bus bar lead wire, antenna or defogger terminal. 6. Apply solder to the underside of the rear defogger bus bar lead wire, antenna or defogger terminal. Draw the soldering iron tip across the fluxed area thinly coating the wire or terminal with solder. Apply heat to the top of the rear defogger bus bar lead wire antenna and/or defogger terminal, causing the solder spot to melt and fuse together. - Use pliers to hold the rear defogger bus bar lead wire, antenna or defogger terminal. - Holding force should not be removed until the solder has solidified. IMPORTANT: Do not overheat the terminal when soldering it to the bus bar. Soldering iron tip temperature should be just enough to melt the solder allowing the solder to run freely. The iron should be in contact with the bus bar for as short a time as possible. 7. Solder the wire or terminal to the bus bar. 8. Wipe off any excess flux. 9. Connect the electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Bus Bar/Antenna Terminal Repair > Page 8574 Heated Glass Element: Service and Repair Grid Line Repair GRID LINE REPAIR TOOLS REQUIRED - J 25070 Heat Gun - Capable of 260°C (500°F) or equivalent - Test Lamp - Rear Window Defogger Repair Kit GM P/N 12346001, Canada P/N 10951643 or equivalent REMOVAL PROCEDURE 1. Disconnect the electrical connector. 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. 1. Inspect the rear window grid lines. 2. Ensure that the rear window is at room temperature. 3. Inspect the grid line area that you will repair. Verify that the area is dry and free from contaminates. 4. Dampen a cloth with isopropyl alcohol. Use the damp cloth in order to wipe the grid line area clean. INSTALLATION PROCEDURE 1. Use a grease pencil in order to mark the grid line break (2) on the outside of the rear window with a grease pencil. IMPORTANT: Ensure that the grid line repair material is not beyond the expiration date. - Repair decal or tape must be used in order to control the width of the repair area. - If the repair decal is used, verify that the die-cut metering slot is the same width as the grid line. - Thoroughly stir the grid line repair material until a uniform color appears. - Verify that there are no air bubbles in the grid line repair material in the repair area. 1. Using GM P/N 12346001 (Canadian P/N 10951643) or equivalent to repair the grid lines. Apply the grid line repair (2) decal or 2 strips of the tape above and below the repair area. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Bus Bar/Antenna Terminal Repair > Page 8575 2. Use the brush (3) in order to spread the grid line repair material (1). Ensure that the repair material covers all of the areas of the cut out. 3. Without disturbing the grid line repair material, carefully remove the decal or tape (2). NOTE: 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. 4. Use a heat gun in order to repair the grid line: - Hold the heat gun nozzle 25 mm (1 in) from the surface. - Heat the repair area for 2-3 minutes. IMPORTANT: Use J 25070 capable of 260°C (500°F) or equivalent. If you do not use a heat gun, allow at least 24 hours at an ambient temperature of 21-32°C (70-90°F) for complete curing of the repair materials. Do NOT physically disturb the repair area until after that time. The grid line will be electrically operative immediately after the repair. 5. Connect the electrical connector. 6. Test the grid line operation in order to verify the grid line repair. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Bus Bar/Antenna Terminal Repair > Page 8576 Heated Glass Element: Service and Repair Rear Window Defogger Braided Lead Wire REAR WINDOW DEFOGGER BRAIDED LEAD WIRE 1. Use a solder containing 3 percent silver and a rosin flux paste in order to solder and attach the rear defogger bus bar lead wire and/or defogger terminal. CAUTION: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. 2. Buff the repair area with a fine steel wool in order to remove the oxide coating that was formed during window manufacture. 3. Use a brush in order to apply the paste-type rosin flux in small quantities to the appropriate area: - The rear defogger bus bar lead wire - The defogger terminal repair area 4. Coat the solder iron tip with solder. Apply only enough heat to melt the solder and only enough solder to ensure a complete repair. CAUTION: Refer to Window Retention Caution in Service Precautions. IMPORTANT: Do not hold the tool in one spot or operate the tool on the window for longer than 30-40 seconds. If the window becomes hot to the touch, allow the window to air cool before proceeding further. Cooling with water may crack the heated window. Avoid excessive pressure in order to ensure that the window will not overheat. 5. Apply the solder to the feed bus bar or the ground bus bar. Draw the soldering iron tip across the fluxed area. Thinly coat the bus bar with solder. 6. Apply a small amount of flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 7. Align the spots with the flux to the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 8. Coat the tip of the soldering iron with solder. 9. Solder the appropriate areas: - The underside of the rear defogger bus bar lead wire - The defogger terminal 10. Draw the iron across the fluxed spot. Thinly coat the spot with solder. 11. Solder the spot on the braid against the spot on the feed bus bar or the ground bus bar. 12. Use pliers in order to hold the appropriate component: - The rear defogger bus bar lead wire - The defogger terminal 13. Apply heat to the appropriate area in order to ensure the solder spot melts and fuses together: - The top of the rear defogger bus bar lead wire - The defogger terminal 14. Remove the excess flux with the solvent. IMPORTANT: Do not remove the holding force until the solder has solidified. 15. Connect the electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Service and Repair > Bus Bar/Antenna Terminal Repair > Page 8577 Heated Glass Element: Service and Repair Rear Window Reveal Molding Replacement REAR WINDOW REVEAL MOLDING REPLACEMENT The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > A/C - Broken Rear Window Defogger Grid Detection > Page 8582 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 8587 Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views Power Window Switch: Connector Views Master Window Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8590 Master Window Switch C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8591 Master Window Switch C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8592 Master Window Switch - (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8593 Window Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8594 Window Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 8595 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to remove the power window switch bezel (1) from the console. 2. Remove the electrical connection from the power window switch (2). 3. With a flat-bladed tool release the power window switch (2) tabs, and remove the switch from the power window bezel (1) retainers. INSTALLATION PROCEDURE 1. Install the power window switch (2) into the power window switch bezel (1) until fully seated. 2. Connect the electrical connector to the power window switch (2). 3. Install the power window switch bezel (1) to the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Connector Views Power Window Motor: Connector Views Window Motor - Driver Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Connector Views > Page 8601 Window Motor - Front Passenger Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Connector Views > Page 8602 Window Motor - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Connector Views > Page 8603 Window Motor - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 8607 Center Console Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views Power Window Switch: Connector Views Master Window Switch C1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8610 Master Window Switch C2 Part 1 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8611 Master Window Switch C2 Part 2 Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8612 Master Window Switch - (Coupe) Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8613 Window Switch - LR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Connector Views > Page 8614 Window Switch - RR Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 8615 Power Window Switch: Service and Repair POWER WINDOW SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Use a flat-bladed tool in order to remove the power window switch bezel (1) from the console. 2. Remove the electrical connection from the power window switch (2). 3. With a flat-bladed tool release the power window switch (2) tabs, and remove the switch from the power window bezel (1) retainers. INSTALLATION PROCEDURE 1. Install the power window switch (2) into the power window switch bezel (1) until fully seated. 2. Connect the electrical connector to the power window switch (2). 3. Install the power window switch bezel (1) to the floor console. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Adhesive Installation of Stationary Windows. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Door Window Channel Replacement Door Window Channel Replacement Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door rear view mirror. 5. Remove the sealing strip, window belt outer. 6. Remove the channel (2) lower bolt (3). 7. Remove the push-in retainer (1) at the top of the channel. 8. Remove the window run channel weather-strip from the front door window (4). Installation Procedure 1. Install the run channel weather-strip (2) to the front door window. 2. Install the push-in retainer (1) at the top of the channel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the channel lower bolt (3). Tighten the upper window channel lower bolt to 6 N.m (53 lb in). 4. Install the sealing strip, window belt outer. 5. Install the front door rear view mirror. 6. Install the front door window. 7. Install the front door water deflector. 8. Install the front door trim panel. Front Side Door Window Rear Channel Replacement Front Side Door Window Rear Channel Replacement Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 8630 Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door window. 4. Remove the front door reveal molding by the window rear channel. 5. Remove the bolt from the rear channel (2). 6. Lift up the rear channel to disengage the top clip. 7. Remove the window rear channel (1) from the front door. Installation Procedure 1. Position the rear run channel (1) in the front door. 2. Lift up the rear channel to install the top clip. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the window rear channel bolt (2). Tighten the lower window channel bolt 6 N.m (53 lb in). 4. Install the reveal molding. 5. Install the front door window. 6. Install the front door water deflector. 7. Install the front door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 8631 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Front Side Door Window Belt Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (1) from the door sealing strip. 3. Remove the door sealing strip (2). Installation Procedure 1. Install the door sealing strip (2). 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (1) to the door sealing strip. Tighten the door sealing strip screw (1) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Rear Side Door Window Front Channel Replacement Removal Procedure 1. Ensure that the window is fully closed. 2. Remove the door trim panel. 3. Remove the water deflector. 4. Remove the window regulator. 5. Lower the window to the bottom of the door. 6. Remove the lower bolt (2). 7. Lift the channel to disconnect the upper fastener. 8. Remove the front window channel (1) from the door. Installation Procedure 1. Position the front window channel (1) in the door, top end first. 2. Insert the channel top retainer into the slot. 3. Rotate the top of the front window channel rearward and align it on the lower edge of the window. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear door window channel lower bolt (2). Tighten the lower window channel bolt to 6 N.m (53 lb in). 5. Lift up the window and install the window regulator. 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 8641 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Rear Side Door Window Outer Sealing Strip Replacement Removal Procedure 1. Move the door window to the full DOWN position. 2. Remove the screw (3) from the door sealing strip. 3. Lift up to remove the door sealing strip (2) from the door. Installation Procedure 1. Position the door sealing strip (2) to the door. 1. Align the end cap with the edge of the door. 2. Press down on the door sealing strip (2) in order to seat the strip. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw (3) to the door sealing strip. Tighten the door sealing strip screw (3) to 2 N.m (18 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair Window Handle: Service and Repair Door Window Regulator Handle Replacement Tools Required J 9886-01 Door Handle Clip Remover Removal Procedure 1. Note the position of the door window regulator handle with the window in the full up position. 2. Place the door window regulator handle in the upward position. 3. Remove the spring clip by inserting J 9886-01 between the window regulator handle and the door window regulator handle bearing plate. Press down to remove the spring clip. 4. Remove the window regulator handle. 5. Remove the door window regulator handle bearing plate. Installation Procedure 1. Position the window to the full up position. 2. Install the spring clip to the door window regulator handle. 3. Install the door window regulator handle bearing plate. 4. Position the door window regulator handle to the regulator. 5. Install the door window regulator handle, press in until fully seated. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Power) Front Side Door Window Regulator Replacement (Power Regulator) Removal Procedure 1. Lower the window to the three quarters down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts (4). 5. Push the window to the closed position and tape in place. 6. Disconnect the regulator electrical connector. 7. Remove the power window regulator bolts (3). 8. Drill out the power window regulator rivets (2). 9. Remove the power window regulator (5) from the door. Installation Procedure 1. Position the power window regulator (5) in the door. 2. Connect the door window regulator electrical connector. 3. Install the power window regulator rivets (2). Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power window regulator bolts (3). Tighten the regulator bolts (3) to 10 N.m (89 lb in). 5. Remove the tape from the window and push the window down to the regulator. 6. Install the power window to regulator nuts (4). Tighten the window to regulator nuts (4) to 10 N.m (89 lb in). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 8650 7. Install the water deflector. 8. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 8651 Front Door Window Regulator: Service and Repair Door Window Regulator Replacement (Manual) Front Side Door Window Regulator Replacement (Manual Regulator) Removal Procedure 1. Position the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the regulator to window nuts. 5. Push the window to the closed position and tape in place. 6. Remove the manual window regulator bolts (3). 7. Remove the manual window regulator rivets (2). 8. Remove the manual window regulator (5) from the door. Installation Procedure 1. Position the manual window regulator (5) in the door. 2. Install the manual window regulator rivets (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator bolts (3). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Replacement (Power) > Page 8652 Tighten the regulator bolts (3) to 10 N.m (89 lb in). 4. Remove the tape from the window and push it down to the regulator. 5. Install the manual window regulator nuts (4). Tighten the regulator nuts (4) to 10 N.m (89 lb in). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Manual Rear Side Door Window Regulator Replacement (Manual Regulator) Removal Procedure 1. Lower the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts. 5. Push the window up to the full closed position and tape in place. 6. Drill out the manual window regulator rivets (3). 7. Remove the power window regulator nuts (2). 8. Remove the manual window regulator (1) from the door. Installation Procedure Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 8657 1. Position the manual window regulator (1) in the door. 2. Install the manual window regulator rivets (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the manual window regulator nuts (2). Tighten the regulator nuts (2) to 10 N.m (89 lb in). 4. Remove the tape from the window and push it down to the regulator. 5. Install the power window to regulator nuts (2). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 8658 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Power Rear Side Door Window Regulator Replacement (Power Regulator) Removal Procedure 1. Lower the window to the three quarter down position. 2. Remove the door trim panel. 3. Remove the water deflector in order to access the window regulator. 4. Remove the window to regulator nuts. 5. Push the window up to the full closed position and tape in place. 6. Drill out the power window regulator rivets (3). 7. Remove the power window regulator nuts (2). 8. Remove the electrical connector. 9. Remove the power window regulator (1) from the door. Installation Procedure 1. Position the power window regulator (1) in the door. 2. Install the power window regulator rivets (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power window regulator nuts (2). Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Manual > Page 8659 Tighten the regulator nuts (2) to 10 N.m (89 lb in). 4. Remove the tape from the window and push the window down to the regulator. 5. Install the power window to regulator nuts (2). 6. Install the water deflector. 7. Install the door trim panel. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair Windshield Moulding / Trim: Service and Repair Stationary Window Reveal Molding Repair Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. Installation Procedure Caution: Refer to Window Retention Caution. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 8665 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Stationary Window Reveal Molding Repair > Page 8666 Windshield Moulding / Trim: Service and Repair Windshield Reveal Molding Replacement Windshield Reveal Molding Replacement The windshield reveal molding is an applied molding design separate from the window. The reveal molding is bonded to the windshield and may be bonded to the body. The reveal molding may be replaced with the windshield as an assembly, or the reveal molding may be available as a separate service part. Refer to Adhesive Installation of Stationary Windows. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8672 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8673 7. Ensure that the windshield wiper switch (2) functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8677 Windshield Wiper Switch Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8678 Wiper Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8679 7. Ensure that the windshield wiper switch (2) functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Pump Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 8683 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Disconnect the washer pump electrical connector. 4. Disconnect the washer pump hose. 5. Using a small flat-bladed tool, remove the washer pump from the washer solvent container. 6. Using a small flat-bladed tool, remove the washer pump seal from the washer solvent container. INSTALLATION PROCEDURE 1. Position the washer pump seal to the washer solvent container, pressing in until fully seated. 2. Position the washer pump to the washer solvent container, pressing in until fully seated. 3. Connect the washer pump hose. 4. Connect the washer pump electrical connector. 5. Lower the vehicle. 6. Fill the washer solvent container with washer solvent. 7. Inspect the washer system for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair WASHER SOLVENT CONTAINER REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Drain the washer solvent from the washer solvent container. 3. Remove the washer solvent container cap. 4. Remove the left front fender liner. 5. Disconnect the anti-lock brake electrical harness from the washer solvent container. 6. Disconnect the washer pump electrical connector. 7. Disconnect the washer pump hose. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 8687 8. Remove the push-in retainer from the air induction tube. 9. Remove the washer solvent container screws. 10. Remove the washer solvent container from the vehicle. 11. Remove the air induction tube screw. 12. Remove the air induction tube from the washer solvent container. INSTALLATION PROCEDURE Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 8688 1. Position the air induction tube to the washer solvent container. 2. Install the air induction tube screw. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 3 N.m (27 lb in). 3. Position the washer solvent container to the vehicle. 4. Install the washer solvent container screws. Tighten Tighten the screws to 10 N.m (89 lb in). 5. Install the push-in retainer to the air induction tube. 6. Connect the washer pump hose. 7. Connect the washer pump electrical connector. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 8689 8. Connect the anti-lock brake electrical harness to the washer solvent container. 9. Install the front fender liner. 10. Lower the vehicle. 11. Install the washer solvent container cap. 12. Fill the washer solvent container with solvent. 13. Inspect the washer system for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8693 Windshield Washer Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 8694 7. Ensure that the windshield wiper switch (2) functions properly. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair WIPER ARM REPLACEMENT TOOLS REQUIRED J 39822 Wiper Arm Puller REMOVAL PROCEDURE 1. Turn the ignition switch to the ACCY position. 2. Turn the wiper switch to the DELAY position. 3. Turn the ignition OFF when the wiper arms are in the innerwipe position and not moving. 4. Mark the position of the wiper arm on the windshield with tape. 5. Disconnect the washer hose from the washer nozzle. 6. Remove the wiper arm nut cover. 7. Remove the wiper arm nut. 8. Using the J 39822 , remove the wiper arm from the wiper transmission. INSTALLATION PROCEDURE 1. Position the wiper arm onto the wiper transmission. 2. Align the wiper arm to the tape marks on the windshield. 3. Install the wiper arm nut. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 8698 Tighten the nut to 30 N.m (22 lb ft). 4. Install the wiper arm nut cover. 5. Connect the washer hose to the washer nozzle. 6. Remove the tape marks from the windshield. 7. Inspect the wipers for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 8703 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement REMOVAL PROCEDURE 1. Press the wiper blade release tab in to release the wiper blade from the inside radius of the wiper arm. 2. Remove the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE 1. Install the hook of the wiper arm through the opening in the wiper blade. 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 8706 3. Press the wiper blade pivot into the wiper arm hook until fully seated.. 4. Inspect the wipers for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 8707 Wiper Blade: Service and Repair Wiper Blade Element Replacement REMOVAL PROCEDURE 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Remove the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE 1. Install the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 8708 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Disconnect the wiper motor electrical connector. 3. Remove the wiper drive system module screws. 4. Remove the wiper drive system module from the vehicle. 5. Using the J 39232 , disconnect the wiper transmission from the wiper motor crank arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 8712 6. Remove the wiper transmission caps. 7. Remove the wiper transmission screws. 8. Remove the wiper transmission from the wiper drive system module tube frame. INSTALLATION PROCEDURE 1. Position the wiper transmission to the wiper drive system module tube frame. 2. Install the wiper transmission screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 9 N.m (79 lb in). 3. Install the wiper transmission caps. 4. Using the J 39529 , connect the wiper transmission to the wiper motor crank arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Page 8713 5. Position the wiper drive system module to the vehicle. 6. Install the wiper drive system module screws. Tighten Tighten the screws to 10 N.m (89 lb in). 7. Connect the wiper motor electrical connector. 8. Install the air inlet grille panel. 9. Inspect the wipers for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Windshield Wiper Motor Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement Wiper Motor: Service and Repair Wiper Motor Cover Replacement WIPER MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor cover screws. 3. Remove the wiper motor cover from the wiper motor. 4. Disconnect the wiper motor electrical connector. INSTALLATION PROCEDURE 1. Connect the wiper motor electrical connector. 2. Position the wiper motor cover onto the wiper motor. 3. Install the wiper motor cover screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the air inlet grille panel. 5. Inspect the wipers for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 8720 Wiper Motor: Service and Repair Wiper Motor Replacement TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement in Body Front End. 2. Disconnect the wiper motor electrical connector. 3. Remove the screws from the wiper drive system module. 4. Remove the wiper drive system module from the vehicle. 5. Using J 39232 , disconnect the transmission from the wiper motor crank arm. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 8721 6. Remove the wiper motor screws. 7. Remove the wiper motor from the wiper drive system module. INSTALLATION PROCEDURE 1. Position the wiper motor to the wiper drive system module. 2. Install the wiper motor screws. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 10 N.m (89 lb in). 3. Using J 39529 , connect the wiper transmission arms to the wiper motor crank arm. IMPORTANT: The motor crank arm pivot is a greased joint to the wiper transmission. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 8722 4. Position the wiper drive system module to the vehicle. 5. Install the wiper drive system module screws. Tighten Tighten the screws to 10 N.m (89 lb in). 6. Connect the wiper motor electrical connector. 7. Install the air inlet grille panel. 8. Inspect the wipers for proper operation. Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Steering Column Components Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8726 Windshield Wiper Switch Assembly Chevrolet Cavalier Workshop Manual (L4-2.2L VIN F (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 8727 Wiper Switch: Service and Repair WIPERS/WASHER SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 2. Remove the steering column trim covers. 3. Remove the multifunction switch. 4. Remove the retaining screw from the windshield wiper switch (2). 5. Disconnect the electrical connector from the windshield wiper switch. 6. Remove the windshield wiper switch (2) from the column (6). INSTALLATION PROCEDURE 1. Connect the electrical connector to the windshield wiper switch (2). 2. Install the windshield wiper switch (2) to the column (6). 3. Install the retaining screw to the windshield wiper switch (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screw to 4 N.m (36 lb in). 4. Install the multifunction switch. 5. Install the steering column trim covers. 6. Connect the negative battery cable.