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2002 Pontiac Grand Prix GT THERMOSTAT REPLACEMENT (3.1 L) MANUAL

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Filed Under (Pontiac Manuals) by admin on 08-05-2012

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THERMOSTAT REPLACEMENT (3.1 L) Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the air cleaner intake duct. Refer to AIR CLEANER INTAKE DUCT . 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System . 3. Use the J 38185 in order reposition the hose clamp from the water outlet housing. 4. Remove the radiator inlet hose from the water outlet housing. 5. Remove the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.1L) or EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) Fig. 74: Radiator Inlet Hose & Water Outlet Housing Courtesy of GENERAL MOTORS CORP. 6. Remove the water outlet housing bolts. 7. Remove the water outlet housing and gasket. Fig. 75: Water Outlet Housing & Bolts Courtesy of GENERAL MOTORS CORP. 8. Remove the thermostat. 9. Clean the water outlet housing mating surfaces Fig. 76: Thermostat & Water Outlet Housing Courtesy of GENERAL MOTORS CORP. Installation Procedure 1. Install the thermostat. 3. Install the water outlet housing bolts. Tighten Tighten the water outlet housing bolts to 25 N.m (18 Ib ft). 4. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT (3.1L) or EXHAUST CROSSOVER PIPE REPLACEMENT (3.8L) . 5. Install the radiator inlet hose to the water outlet housing.

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Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination)

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Filed Under (More Manuals) by admin on 19-05-2012

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2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: Subject: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) Models: 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • 4. With the key off, connect the coolant level sensor into the vehicle’s wiring harness. Connect a ground wire (1) to the battery negative terminal. Using a sharp probe (3) attached to the ground wire, ground the coolant sensor probe (2) as shown in the illustration. Make sure a good contact is made. With the key on and the engine off, observe the low coolant light for at least 15 seconds. 5. Using a small wire brush or emery cloth, polish the low coolant level sensor probe to remove any film or oxidation. The probe should be a bright brass color when finished. Use Brake Parts Cleaner to flush removed deposits from the low coolant sensor probe. Reinstall the low coolant sensor into the vehicle and proceed to Step 6. 6. Flush the cooling system and install new DEX-COOL® mixture as outlined in the SI. Check the vehicle’s warranty history to determine if any engine gasket had recently been changed. If there has not been a recent gasket replacement, locate and repair the source of the engine oil contamination

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2000 Pontiac Montana THERMOSTAT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Pontiac Manuals) by admin on 07-02-2012

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Removal & Installation 1. Remove the air cleaner and duct assembly. See Fig. 10 . Drain the coolant until the coolant level is below the thermostat. See COOLING SYSTEM BLEEDING . 2. Remove the crossover exhaust pipe. See Fig. 11 . Remove the radiator hose from the thermostat housing. 3. Remove the thermostat housing bolts and clean any sealer from the bolt threads. See Fig. 12 . Remove the thermostat housing and gasket. 4. Remove the thermostat. Inspect and clean the mating surfaces. 5. Install the thermostat housing and gasket. Install RTV sealer (GM P/N 1052366) to the thermostat housing bolt threads. Install the thermostat housing bolts. See TORQUE SPECIFICATIONS . 6. To complete installation, reverse removal procedure. Fill the cooling system. Inspect the cooling system for leaks. Repair as necessary.

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4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly)

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Filed Under (More Manuals) by admin on 07-07-2012

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2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission this service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, four other gaskets not included in this service kit will also be needed to complete the repair, a Control Valve Body Cover (Side Cover) Gasket (54), a Control Valve Body Cover (Side Cover) Inner Gasket (59), a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering service kit P/Ns 24206959 and 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to- Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY . To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B).

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2006 Saturn ION L4-2.2L VIN F Window Regulator Replacement – Front Door (Power Regulator) removal and installation procedure

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Filed Under (Saturn Manuals) by admin on 05-01-2012

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Removal Procedure 1. Lower the window to the full down position. 2. Remove the door trim panel . Refer to Trim Panel Replacement – Side Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ReplacementTrim Panel Replacement – Side Front Door ) . 3. Remove the radio speaker. Refer to Speaker Replacement – Front Door in Entertainment. 4. Remove the water deflector in order to access the window regulator. Refer to Water Deflector Replacement – Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door ) . 5. Disengage the door glass to the regulator sash channel clips (2). Separate the door glass from the sash channel (1). 6. Push the window to the up position and tape in place. 7. Loosen the power window regulator bolts. Remove the rear regulator bolt. 8. Lift the window regulator, disengaging the loosened bolts from the door. 9. Disconnect the regulator electrical connector. 10. Remove the power window regulator from the door. Installation Procedure 1. Loosely install the four forward fasteners into the window regulator. 2. Position the power window regulator in the door. 3. Connect the door window regulator electrical connector. Notice: Refer to Fastener Notice in Cautions and Notices. 4. Install the power window regulator bolts. Tighten the regulator bolts to 10 N.m (89 lb in). 5. Remove the tape from the window. Push the window down to the regulator sash channel. 6. Slide the glass sash clips (2) into the window regulator sash channel (1). 7. Install the water deflector. Refer to Water Deflector Replacement – Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ComponentsWater Deflector Replacement – Front Door ) . 8. Install the radio speaker. Refer to Speaker Replacement – Front Door in Entertainment. 9. Install the door trim panel . Refer to Trim Panel Replacement – Side Front Door ( See: Body and FrameDoors, Hood and TrunkFront Door PanelService and RepairFront Door Panel ReplacementTrim Panel Replacement – Side Front Door

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2002 Chevrolet Chevy Suburban – 4WD Intake Manifold Replacement Manual

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Filed Under (Chevrolet Manuals) by admin on 13-05-2011

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Removal Procedure Important: The intake manifold, throttle body, fuel rail, and injectors may be removed as an assembly. If not servicing the individual components, remove the manifold as a complete assembly. 1. Remove the throttle body. Refer to Throttle Body Assembly Replacement in Engine Controls – 4.8L, 5.3L, and 6.0L. 2. Remove the fuel injectors. Refer to Fuel Injector Replacement in Engine Controls – 4.8L, 5.3L, and 6.0L. 3. Disconnect the following electrical connectors: 4. Remove the knock sensor harness electrical connector from the intake manifold. 5. Set the electrical harness aside. <- Back Forward -> Document ID# 738735 2002 Chevrolet Chevy Suburban – 4WD Print – Manifold absolute pressure (MAP) sensor (1) – Knock sensor (2) – Exhaust gas recirculation (EGR) valve, if equipped. 6. If equipped, remove the following EGR pipe bolts: 7. If equipped, remove the EGR pipe with valve. 8. If equipped, remove the EGR pipe gasket from the exhaust manifold If equipped with vacuum assisted brakes, remove the vacuum brake booster hose from the rear of the intake manifold.

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Various Concerns With Shifter and/or Ignition Key (Replace Shifter Assembly/Shifter Components or Ignition Lock Cylinder )

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Filed Under (More Manuals) by admin on 05-05-2012

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2005-2007 Chevrolet Cobalt 2005-2006 Pontiac Pursuit (Canada Only) 2007 Pontiac G5 with Automatic Transmission 4T45-E (RPO MN5) The illustration above shows the switch in a correct position. Cause 3 Metal flashing left in the cylinder may cause a high effort to rotate the key. Cause 4 The slider may be binding in the guides. This may cause the shifter to become difficult to operate. Correction 1 Verify that the shifter button is inoperative by evaluating if the park pawl pin on the shifter assembly moves when activating the button. If the parking pawl does not move when the button is activated, the shifter handle will have to be replaced. Refer to Floor Shifter Control Knob Replacement in SI. Correction 2 Important: A change has been made to the shifter assembly for service. The replacement shifter assembly will read PRNDIL (Park, Reverse, Neutral, Drive, Intermediate and Low). Verify that the micro switch is out of position. Replace the shifter assembly. Refer to Transmission Control Replacement in SI. Correction 3 Important: Refer to instruction sheet that is supplied with the lock cylinder kit. BO 47869 is an essential staking tool and must be used for the repair. Replace the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement in SI. Correction 4 Replace the slide indicator and guides in the shifter following the procedure below: 1. Apply the parking brake. 2. Remove the upper console trim. Refer to Trim Plate Replacement-Console Front in SI. 3. Remove shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 4. Remove the indicator plate. Use a flat-bladed screwdriver to release the locking tabs. 5. Remove the shifter indicator lens. 6. Pull up on the indicator and remove it from the assembly. 7. Remove the two front rails by unsnapping the front and lifting up, and then back, to remove the rails from the shifter assembly. 8. Install the new guides. Place the hook end into the assembly and push down. It will snap into place. 9. Install the new slide indicator. With the transmission in neutral, place the slide over the shifter and into the guides. Move the slide indicator down the guides in the front and rear. Important: Replace the shifter indicator lens if damage is present due to the slider binding or if it becomes damaged during disassembly. 10. Install the shift indicator lens. 11. Install the shift indicator plate. 12. Install the shifter knob. Refer to Floor Shifter Control Knob Replacement in SI. 13. Install the upper console trim. Refer to Trim Plate Replacement-Console Front in SI

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2003 GMC Truck C 1500 P/U 2WD Engine Knocking or Lifter Noise

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Filed Under (GMC Manuals) by admin on 30-06-2012

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Engine Lubrication: All Technical Service Bulletins Engine – Knocking or Lifter Noise File In Section: 06 – Engine/Propulsion System Bulletin No.: 02-06-01-038 Date: December, 2002 TECHNICAL Subject: Engine Knock or Lifter Noise (Replace 0-Ring) Models: 2001-2002 Chevrolet Camaro 2001-2003 Chevrolet Corvette 2001-2002 Pontiac Firebird 2002-2003 Cadillac Escalade, Escalade EXT 2000-2003 Chevrolet Suburban, Tahoe 2001-2003 Chevrolet Silverado 2002-2003 Chevrolet Avalanche 2000-2003 GMC Yukon, Yukon XL 2001-2003 GMC Sierra with 4.8L, 5.3L, 5.7L or 6.0L V8 Engine (VINs V, T, Z, G, S, N, U – RPOs LR4, LM7, L59, LS1, LS6, LQ9, LQ4) Condition Some customers may comment on an engine tick noise. The distinguishing characteristic of this condition is that it likely will have been present since new, and is typically noticed within the first 161-322 km (100-200 mi). The noise may often be diagnosed as a collapsed lifter . Additionally, the noise may be present at cold start and appear to diminish and then return as the engine warms to operating temperature. This noise is different from other noises that may begin to occur at 3219-4828 km (2000-3000 mi). Cause The 0-ring seal between the oil pump screen and the oil pump may be cut, causing aeration of the oil. Correction

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2000-2002 Infiniti G20 MIL “ON” REAR O2 SENSOR DTC P0138/P0139/P0140 Repair Manual

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Filed Under (Infiniti Manuals) by admin on 17-02-2012

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SERVICE PROCEDURE You will be performing the following, as required: • Determine the DTC Stored in ECM from the CONSULT-II Self-diagnosis results. • ECM Part Number Check to determine if this bulletin applies. • ECM Reprogramming (required if the ECM P/N in the vehicle matches one of those listed under “Current ECM P/N” in Chart A -page 2). • Replacing the Rear Oxygen Sensor (required if ECM Reprogramming is needed). Determine the DTC Stored in ECM: 1. Determine which DTC code is stored in the vehicle’s ECM by performing CONSULT-II Self-Diagnosis. 2. Print out the Self-Diagnosis results for use in ECM Part Number Check , below. See Figure 1 for an example of the CONSULT-II Self-Diagnosis printout. Figure 1 SELF-DIAG RESULTS SYSTEM ENGINE DATE 03/15/2002 3:35:35 P/N 23710-7J400 DTC Code TP020169 DTC RESULTS TIME HO2S2 (B1) 3 [P0138] Current ECM Part Number 2/3 ECM Part Number Check 1. Compare the vehicle’s current ECM P/N (from your CONSULT-II Self Diagnosis printout) to those shown under Current ECM P/N in Chart A , below: Chart A – Current ECM P/N’s: Vehicle Current ECM P/N 2000 M/T 23710-7J400, -7J401, -7J402, -7J460 2000 A/T 23710-7J410, -7J411, -7J412, 7J470 2001-2002 M/T 23710-6J105, -6J106, -6J107, -6J108, 6J170 2001-2002 A/T 23710-6J115, -6J116, -6J117, -6J118, -6J180 A. If the ECM P/N in the vehicle matches one of those listed under “Current ECM P/N” in Chart A (above): • Look in the “Vehicle” Column in Chart A (above) and determine the vehicle “configuration” (i.e. 2002 M/T). Make a note of the vehicle configuration and perform ECM Reprogramming , below. B. If the ECM P/N in the vehicle does not match one of those listed under “Current ECM P/N” in Chart A (above): • This bulletin does not apply. Use the appropriate Electronic Service Manual (ESM) to further diagnose and repair the incident. ECM Reprogramming 1. Perform ECM Reprogramming to install the latest available ECM data. • If you are unfamiliar with ECM Reprogramming, click here to link to the “ECM Reprogramming For Infiniti Vehicles” general procedure or refer to Attachment A in the print copy of this bulletin. • For those familiar with ECM Reprogramming, perform the following:

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2002 Daewoo Leganza SE Dashboard / Instrument Panel Service and Repair Manual

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Filed Under (Daewoo Manuals) by admin on 02-02-2012

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Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the floor console. 3. Remove the sun sensor and the automatic temperature controls assembly. 4. Remove the tweeter speakers and the stereo cassette AM/FM radio. Refer to Section 9F, Audio Systems. 5. Remove the screws and the instrument panel storage compartment. 6. Remove the instrument cluster dimmer switch assembly. 7. Remove the instrument cluster. 8. Remove the chime module. 9. Remove the kick panels. 10. Remove the glove box. 11. Remove the screws and the glove box housing. 12. Disconnect the glove box housing electrical connectors. 13. Remove the knee bolster. 14. Remove the nuts and the bolts securing the steering column. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 2 15. Disconnect the steering column electrical connectors. 16. Lower the steering column. 17. Remove the screw behind the stereo cassette AM/FM radio. 18. Remove the screw securing the instrument panel to the heater air distributor case. 19. Remove the bolts and the glove box brace. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 3 20. Remove the instrument panel screw behind the glove box brace. 21. Remove the instrument panel bolts below the windshield. 22. Remove the bolts securing the bottom of the instrument panel to the floor. 23. Remove the bolts securing the sides of the instrument panel to the body. 2002 Daewoo Leganza SE L4-2.2L DOHC D-TEC MFI Page 4 24. Disconnect the instrument panel electrical connectors. 25. Remove the instrument panel. Installation Procedure 1. Position the instrument panel in the vehicle. 2. Connect the instrument panel electrical connectors. NOTE: Dissimilar metals in direct contact with each other may corrode rapidly. Make sure to use the correct fasteners to prevent premature corrosion. 3. Install the bolts securing the sides of the instrument panel to the body. Tighten Tighten the instrument panel-to-body bolts to 22 N.m (16 lb-ft) . 4. Install the bolts securing the bottom of the instrument panel to the floor. Tighten Tighten the instrument panel-to-floor bolts to 22 N.m (16 lb-ft) .

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